Multiquip DCA800SSK User Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

MODEL DCA-800SSK

PORTABLE GENERATOR

(STANDARD)

Revision #4 (06/03/10)

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Diesel engine exhaust and some of

PAGE 2 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

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

DCA-800SSK TABLE OF CONTENTS

MQ Power DCA-600SSKMQ Power DCA-600SSK

MQ Power DCA-600SSK

MQ Power DCA-600SSKMQ Power DCA-600SSK AC GeneratorAC Generator

AC Generator

AC GeneratorAC Generator

Here's How To Get Help .................................................... 3

Parts Ordering Procedures ............................................... 5

Specifications Generator/Engine ...................................... 6

Dimensions (Top and Side) ............................................... 8

Dimensions (Front and Rear) ............................................ 9

Safety Alert Messages Symbols ............................... 10-11

Rules for Safe Operation ........................................... 12-15

Installation ................................................................. 16-17

Towing Rules for Safe Operation .................................... 18

Trailer Safety Guidelines ................................................. 19

Trailer Specifications ................................................. 20-21

Operation and Safety Decals ..................................... 22-25

General Information ........................................................ 26

Major Components ......................................................... 27

Generator Control Panel (Up to S/N 3698616) ................ 28

Generator Control Panel (S/N 3698617~)........................ 28

Generator Control Panel Description ............................... 29

Engine Operating Panel (Up to S/N 3698616) ................. 30

Engine Operating Panel (S/N 3698617~) ........................ 30

Engine Operating Panel Description ............................... 31

Output Terminal Panel Overview ................................ 32-34

Load Application ............................................................. 35

Generator Outputs .......................................................... 36

Generator Outputs/Gauge Reading ................................. 37

Output Terminal Panel Connections ........................... 38-39

Pre Setup .................................................................. 40-44

Generator Start-up Procedure (Key Switch) .............. 45-47

Generator Start-up Procedure ( Manual MPEC) ............. 48

Generator Start-up Procedure (Auto MPEC) .................. 49

Generator Shutdown Procedure ...................................... 50

Maintenance .............................................................. 51-55

Trailer Brakes Maintenance ............................................ 56

Trailer Maintenance .................................................... 57-58

Trailer Wiring Diagrams .............................................. 59-60

Generator Wiring Diagram ............................................... 61

Generator Main breaker Wiring Diagram ......................... 62

Engine Wiring Diagrams ............................................ 63-64

Electronic Governor Controller Wiring Diagram ............... 65

Engine Troubleshooting .............................................. 66-67

Generator Troubleshooting .............................................. 68

Engine Contoller Troubleshooting (MPEC) ...................... 69

Explanation of Codes in Remarks Column ..................... 70

Suggested Spare Parts .................................................. 71

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .......................................... 72-75

Control Box Assembly ........................................ 76-81

Engine and Radiator Assembly .......................... 82-85

Oil Drain Assembly ............................................. 86-87

Engine Operating Panel Assembly .................... 88-89

Output Terminal Assembly ................................. 90-93

Battery Assembly ............................................... 94-95

Muffler Assembly ............................................... 96-97

Fuel Tank Assembly ........................................... 98-99

Enclosure #1 Assembly.................................. 100-103

Enclosure #2 Assembly.................................. 104-107

Enclosure #3 Assembly.................................. 108-111

Enclosure (Rubber Seals) .............................. 112-113

Name Plate and Decals ................................. 114-117

Terms and Conditions Of Sale — Parts ................ 118

NOTE

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

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

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

N View Parts Diagrams

N Order Parts N Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Parts

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact your District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R Quantity, Part Number and Description of Each Part

www.mqpower.com

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 5

When ordering parts, please supply:

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Tr uck  N Ground N Next Day N Second/Third Day

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA-800SSK — SPECIFICATIONS

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tuptuOybdnatS)WK047(AVK088

tuptuOemirP)WK046(AVK008

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ycneuqerFzH06

rotcaFrewoP8.

)A(BdleveLdnuoS)teef32tadaollluf(37

ledoM041V21VSUSTAMOK

suonorhcnysepytdetcetorpnepo,detalitnevfles,dleifgnivloveR

rotareneg

044,614,042,022,802

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)esahpelgnis(elbatsujda772,452,042,931,721,0021

snoitacificepSenignE

epyT relooc-retfahtiwdegrahc-obrut,noitcejnitcerid

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PAGE 6 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

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tuptuOdetaRmpr0081/PH689

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NOTE PAGE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 7

DCA-800SSK — DIMENSIONS (TOP AND SIDE)

Figure 1. Dimensions

PAGE 8 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK— DIMENSIONS (FRONT , REAR AND DOORS)

Figure 2. Dimensions

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 9

DCA-800SSK — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in

injury to yourself and others.

This

NOTE

Operation and Parts

has been developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-800SSK (60Hz)

Manual

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

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

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-800SSK — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the engine ON/OFF

switch in the OFF position when the generator is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

This generator, other property,

NOTE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 11

or the surrounding environment could be damaged if you do not follow instructions.

DCA-800SSK — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-800SSK

or even

DEATH

! This equipment is to be

(60 Hz) Whisperwatt

™

Generator

General Safety:

■

DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other

ALWAYS check the machine for loosened threads or bolts before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

bodily harm or even death.

NEVER

operate the generator in any

■

protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

NEVER run engine without air filter. Severe engine damage may occur.

DO NOT leave the generator running in the unattended.

Refer to the engine technical questions or information.

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

Komatsu Engine Owner's Manual

manual mode

for

PAGE 12 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

The following safety recommendations should also be followed:

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock.

NEVER grab or touch a live power cord with wet hands.

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

Backfeed to a utility system can cause

electrocution

and or property

damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 13

DCA-800SSK — RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handling or servicing the generator.

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, safety glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the battery to

■■

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

clothing or skin

always

severe injury

EYES

wear

DEATH:

, rinse skin or clothing

, rinse eyes immediately with

■

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 14 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — RULES FOR SAFE OPERATION

Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

DOT Requirements include the following:



Connect and test electric brake operation.



Secure portable power cables in cable tray with tie wraps.

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Trailer tires should be inflated to 50 psi cold.

Department of

, before

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

■

ALWAYS know the location of the nearest phone or

the job site,

■

ALWAYS have easy access to the phone numbers of the nearest and

Fire Department

be invaluable in the case of an emergency.

chock blocks

support blocks

fire extinguisher

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

first aid kit

keep a phone on

in case of emergencies.

Ambulance, Doctor

. This information will

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 15

DCA-800SSK — INSTALLATION

DCA-600SSK — INSTALLATION

Figure 3. Typical Generator Grounding Application

PAGE 16 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of

bystanders

, and

overhead obstructions

. Make sure the

debris

generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine

a. Copper - 10 AWG (5.3 mm

b. Aluminum - 8 AWG (8.4 mm2) or larger.

and alternator parts.

2. When grounding the generator (Figure 3) connect the ground cable between the lock washer and the nut on

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed

the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried aminimum of 8 ft. into the ground.

to a ventilated area.

) or larger.

Indoor Installation

NOTE

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 17

DCA-800SSK — TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

■

ALWAYS attach trailer's safety chain to bumper of towing vehicle.

CAUTION - TOWING REGULATIONS

Check with your county or state safety towing regulations before towing your generator.

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 4) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both the towing vehicle and the trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

Remember the maximum speed unless otherwise posted for highway towing is 45 MPH. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place while parked.

■

Place prevent

■

Use the trailer's hand winch to adjust the height of the trailer, then insert locking pin to lock wheel stand in place, while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

tipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling,

Figure 4. Generator and Trailer

PAGE 18 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — TRAILER-SAFETY GUIDELINES

CAUTION - TRAILER INSPECTION

ALWAYS make sure the trailer is in good operating con-

dition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions when reading Table 3.

1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, including the fuel cell (empty).

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 17 and Figure 67 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

4. Frame Length - Measurement is from the ball hitch to

the rear bumper (reflector).

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 19

DCA-800SSK — TRAILER-SPECIFICATIONS

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PAGE 20 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — TRAILER-SPECIFICATIONS

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DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 21

DCA-800SSK — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-800SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustrations below and on the preceding pages shows the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 22 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OPERATION AND SAFETY DECALS

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 23

DCA-800SSK — OPERATION AND SAFETY DECALS

PAGE 24 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OPERATION AND SAFETY DECALS

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 25

DCA-800SSK — GENERAL INFORMATION

DCA-600SSK FAMILIARIZATION Generator

The MQ Power Model DCA-800SSK is a 640 kW that has been designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Control Panel

The “Engine Control Panel” is provided with the following:



Tachometer



Water Temperature Gauge



Oil Pressure Gauge



Oil Filter Alarm Lamp



Charging Ammeter Gauge



Engine Warning Lamp Module



Air Cleaner Indicator



Engine Speed Switch



Pre-Heat Button



Pre-Heat Lamp



Emergency Stop Button



Battery Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following:



Output Voltage Adjustment Knob



Frequency Meter (Hz)



AC Ammeter (Amps)



AC Voltmeter (Volts)



Ammeter Change-Over Switch



Voltmeter Change-Over Switch



Panel Light



Panel Light Switch



MPEC Module



Circuit Breaker ON/OFF Lamps



Circuit Breaker ON Switch



Circuit Breaker Reset Switch



Pilot Lamp

generator

Open Delta Excitation System

The DCA-800SSK generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C, and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load up to the horsepower of the engine.

Engine

The DCA-800SSK is powered by a 6 cylinder, water cooled, turbocharged KOMATSU Model SA12V140 diesel This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-800SSK generator are addressed on the following pages.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

engine.

Microprocessor Controlled Alarm System

The DCA-800SSK generator is equipped with various alarms and LED status indicators. These alarms and status indicators are provided to add safety to the generator when operating under normal conditions. The DCA-800SSK generator is designed to shutdown in the event of low oil, high coolant temperature, low battery and other operation conditions that may cause severe damage to the generator.

PAGE 26 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Electronic Governor System

The electronic governor system is made up of two parts, an electronic controller that monitors frequency variation as the load increases and decreases, and an electronic actuator that controls the engine throttle. The frequency is regulated at ±0.25 to help protect sensitive equipment.

DCA-800SSK — MAJOR COMPONENTS

DCA-600SSK — MAJOR COMPONENTS

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DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 27

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DCA-800SSK — GENERATOR CONTROL PANEL

Up to S/N 3699247

S/N 3699248~

Figure 6. Generator Control Panel

PAGE 28 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the DCA-800SSK "

1. Circuit Breaker OFF lamp - This indicates the main circuit

breaker is "OFF" and the generator is unable to supply power to the load.

2. Circuit Breaker ON lamp - This indicates the main circuit

breaker is in "ON" and the generator is able to supply power to the load.

3. Circuit Breaker Reset Switch - This button will turn off

the circuit breaker.

4. Circuit Breaker Switch - This button will turn on the main

circuit breaker.

5. Pilot Lamp – Indicates that the generator is working

properly.

6. Panel Light – Normally used in dark areas or at night time.

When activated, panel lights will illuminate. When lit this light will make it easier to read the meters and gauges. When the generator is not in use be sure to turn the panel light switch to the OFF position.

7. Frequency Meter - Indicates the output frequency in hertz

(Hz). Typical reading is 60Hz.

8. AC Ammeter - Indicates the amount of current the load is

drawing from the generator.

9. AC Voltmeter - Indicates the single phase output voltage

present at the UVW terminals.

10. Voltage Regulator Control – Allows manual adjustment

of the generator’s output voltage.

11. Ammeter Change-Over Switch - This switch allows the

AC ammeter to indicate the current flow into the load connected to any phase of the output terminals or to be switched off.

12. Voltmeter Change-Over Switch - This switch allows the

AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

13. Panel Light Switch - When activated will turn on control

panel light.

14. Engine Controller - This unit

(S/N 3699248~) contains a vertical row of status LED's (inset), that when lit, indicates an engine malfunction (fault) has been detected. When a fault has been detected by the Engine Controller as a major fault, it will shut down the generator.

Control Panels

" (Figure 9).

During crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller's " Over Crank Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the "Over Speed Protection" mode.

Also the engine controller will shutdown the generator in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the engine controller module.

A. Off/ Manual/ Auto Switch – This switch controls the running

B. Low Oil Pressure – Indicates the engine pressure has

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has attempted

E. Overspeed Shutdown – Indicates that the engine is

F. Engine Running – Indicates that engine is running at a

15. Throttle Lever (Up to S/N 3699247) - This handle

cranking cycle

of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the

manual

If the generator is to be connected to a building's AC power source via a transfer switch (isolation), place the switch in the the AC line output from the building's power source.

fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

temperature has exceeded 215 is detected using variable resistive values from the temperature sending unit. This is considered a

to be started a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. Typical programmable start settings is 3 cycles with a 10 second duration .This is considered a

major

running at an unsafe speed. This is considered a fault.

safe operating speed.

controls the speed of the engine (low or high).

, The engine controller will attempt to

position, the generator will start immediately.

auto

position. In this position the generator will monitor

major

fault.

F. The engine temperature

major

fault.

major

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 29

DCA-800SSK — ENGINE OPERATING PANEL

Up to S/N 3699247

S/N 3699248~

Figure 7. Engine Operating Panels

PAGE 30 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-800SSK "

Engine Operating Panels

" (Figure 11).

1. Air Cleaner Indicators – When lit, indicates air cleaner

must be serviced or replaced. This engine of this generator requires two air cleaners.

2. Battery Switch – This switch should be set to the "ON"

position during normal operation. When the engine has been stopped, place this switch in the "OFF" position. DO NOT turn this switch during normal operation; it will cause damage to the electrical equipment.

3. Ignition Switch (Up to S/N 3699247) – Four position

switch, key to start and stop engine.

pre-heat, stop, run

and

start

. Insert ignition

4. Preheat Lamp – Indicates that the glow plugs of the

diesel engine are hot is ready to start.

5. Emergency Stop Button – Press this button to stop the

engine in the event of an emergency. DO NOT use this button as a normal means of stopping the engine.

6. Oil Filter Alarm Lamp – Indicates the oil filter is clogged

and needs replacement.

7. Engine Warning Display (LED) Module – This module

display’s the following engine failures:

A. Overheat Lamp - This lamp turns on when

the cooling water temperature rises beyond normal level. If the this light is on, the emergency shutdown device will stop the

E. Clogged Air Filter Lamp - This indicates

the air filter is clogged. Stop the engine and replace the air filter.

8. Tachometer - Indicates engine speed in RPMs for 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 indicates the oil

pressure. During normal operation, the gauge should read in the 'green' zone. When starting the generator, the oil pressure may read slightly higher, but after the engine warms up, it should return to the "

9. Water Temp Gauge - This indicates the temperature of the

coolant. During normal operation this gauge should read in the 'green' zone.

11. Charging Ammeter Gauge - This gauge indicates the

current supplied by the alternator, which supplies current from the generator's control circuits and battery charging system.

12. Fuel Level Gauge - This gauge indicates diesel fuel level.

13. Engine Speed Switch

changes the engine speed from

14. Preheat Button – Press and hold this button for

30seconds until the preheat lamp is lit (ON).

engine.

green

" zone.

(S/N 3699248~) – This switch

low

(idle) to

high

B. Low Oil Pressure Lamp - This lamp will

turn on if the Auto-OFF/Reset-Manual switch on the Engine Controller is set in "Manual" position. It will remain lit until the oil pressure is at a normal level. If the lamp turns on at any time during the normal working time of the generator, it will shut down the engine.

C. Low Fuel Level Lamp - When lit, this

indicates to add fuel. Let the engine cool before adding diesel fuel.

D. Low Battery Fluid Lamp - This indicates

the battery fluid level is low. This indicator will shut down the engine. Refill the battery with distilled water.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 31

DCA-800SSK — OUTPUT TERMINAL OVERVIEW

Output Terminal Familiarization

The “

Output Terminal Panel

the following:



Three 240/139V output receptacles, 50 amp



Three AUX. circuit breakers 240V @50 amps



Two 120V GFCI receptacles, 20 amp



Two (2) GFCI circuit breakers 120V@ 20 amps



Eight (16) output terminal lugs

Figure 8. Output Terminal Panel

” (Figure 8) is provided with

Output Terminal Panel

Shown below (Figure 8) is the up on the cover to gain access to receptacles and terminal lugs.

NOTE

Output Terminal Panel

Terminal legs "O" and "Ground" are considered

bonded grounds

, lift

PAGE 32 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OUTPUT TERMINAL PANEL OVERVIEW

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any

board

position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the UVWO terminals.

Pressing the being tripped. Pressing the " the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

Test Button

voltage change-over

" (See Figure 9) in

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the UVWO terminals.

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Figure 11. Voltage Regulator Control Knob

Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face plate cover (Figure 12). Un-lock the locking latch, and lift the terminal cover to gain access to the plastic face plate. Remove the screws securing the face plate to the terminal enclosure, then lift the plastic hinged face plate.

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

After the load wires have been securely attached to the UVWO terminals, reinstall the plastic face plate. Place the

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 240/139 VAC Receptacles

There are three 240/139 VAC, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can be accessed in any

voltage change-over board

position.

terminal cover in the down position and secure the locking latch.

Figure 12. Plastic Face Plate (UVWO Terminals)

Figure 10. 240/139 VAC Twist-Lock

Auxiliary Receptacles

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 33

DCA-800SSK — OUTPUT TERMINAL PANEL OVERVIEW

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 attempting to connect a load to the generator.

To protect the UVWO output terminals from overload, a 3pole, 1,600 amp, sure to switch prior to starting the engine.

main

circuit breaker is provided. Make

ALL

circuit breakers to the "OFF" position

Over Current Relay

over current relay

circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the rent relay must be pressed. The over current relay is located in the control box.

(Figure 14) is connected to the main

reset button

Figure 14. Over Current Relay

on the over cur-

Figure 13. Connecting Loads

Maximum Power Output (KW)

The entire load connected to the UVWO output terminal lugs, duplex and auxiliary receptacles must not exceed 704 kW in standby or 640 kW in prime output.

PAGE 34 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK— LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

frequency requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 5.

WATTS = VOLTAGE x AMPERAGE



The power factor of this generator is 0.8. See Table 5 below when connecting loads.

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When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.



When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW)

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

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

Motors and motor-driven equipment draw much greater current for starting than during operation.

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DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 35

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

If 3Ø load (kVA) is not given on the equipment nameplate,

NOTE

approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

DCA-800SSK — GENERATOR OUTPUTS

Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the

voltage change-over board

(Figure 15).

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the

lator

(VR)

control knob

located on the control panel.

voltage regu-

Voltage Change-Over Board

voltage change-over board

The

(Figure 15) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

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085110,3447,1115,1278

046323,3529,1766,1269

Figure 15. Voltage Change-Over Board 240V Configuration

CAUTION - CHANGING JUMPER PLATES

NEVER attempt to place jumper plates on the

change-over board

There exists the possibility of

while the generator is in operation.

electrocution, electrical

voltage

shock or burn, which can cause severe bodily harm or even death!

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PAGE 36 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR OUTPUTS/GAUGE READING

Maximum Amps

Table 10 shows the vide. DO NOT exceed the maximum amps as listed.

maximum

:ledoMKSS006ACD

amps the generator can pro-

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Figure 17. AC Voltmeter

Change-Over Switch

How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø, 240V operation (See Figure 16), place the

Change-Over Switch

the

AC Ammeter Change-Over Switch

(Figure 17) to the W-U position and

AC Voltmeter

(Figure 19) to the U

Figure 19. AC Ammeter

Change-Over Switch

or W position to read the output on the selected leg.

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 20. AC Ammeter

(Amp reading on U lug)

The

NOTE

ammeter

gauges are only active when the

and

voltmeter

UVWO terminals are in use.

Figure 16. Voltage Change-Over Board 240V Configuration

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 37

DCA-800SSK — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the

Voltage Change-Over Board Voltage Regulator Control Knob

Remember the voltage change-over board determines the

range

of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation

as shown in Figure 21.

and the adjustment of the

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 21 .

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

Figure 23. Voltage Regulator Knob

Figure 21. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 22.

1Ø-139V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 21.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

Figure 22. UVWO Terminal Lugs

3Ø-240V Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

Figure 24. UVWO Terminal Lugs

1Ø-240V Connections

Figure 25. UVWO Terminal Lugs

1Ø-139V Connections

PAGE 38 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 26. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate

must

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 26.

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

be used.

Figure 26. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 26.

Figure 28. UVWO Terminal Lugs

1Ø-480V Connections

Figure 27. UVWO Terminal Lugs

3Ø-480V Connections

ALWAYS make sure that the

NOTE

connections to the UVWO terminals are The possibility of arcing exists, that could cause a fire.

secure

and tight.

DANGER - UVWO OUTPUT TERMINALS

NEVER attempt to connect a load to the UVWO output

terminals while the generato exists of serious injury, electrical shock, electrocution even death.

is operating. The possibility

2. Connect the load wires to the UVWO terminals as shown in Figure 29.

Figure 29. UVWO Terminal Lugs

1Ø-277V Connections

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 39

DCA-800SSK — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 800 amp,

main

circuit breaker is provided to protect the UVWO output

terminals from overload. In addition two single-pole, 20 amp

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

load

circuit breakers

have also been provided to protect the auxiliary receptacles

ALL

from overload. Make sure to switch

circuit breakers to

Fuel Check

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

the "OFF" position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. Also verify that the oil level is maintained between the two notches (Figure 30) on the dipstick. See Table 11 for proper selection of engine oil.

REFILLING THE FUEL SYSTEM

The DCA600SSK series generators may (if equipped with a trailer or skid) have a which consists of an

trailer mounted

can be equipped with a The skid type fuel system does not use the internal generator fuel tank.

hot

engine can cause a

double fuel tank system

internal

generator fuel tank, and a

fire

explosion

(Figure 31),

fuel tank. It is also possible the generator

skid mounted

fuel tank (Figure 32).

Use the instructions in this section that applies to your type

Figure 30. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Komatsu Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:



API Service Classification CH-4



API Service Classification CG-4



API Service Classification CF-4



ACEA Specification E3



ACEA Specification E2

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of fuel tank system.

ALWAYS fuel.

DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 31 Double Fuel Tank System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personnel who have read and

understand this section should refill the fuel tank system.

fill the fuel tank with clean and fresh

#2 diesel

PAGE 40 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — PRE-SETUP

CAUTION - TRAILER FUEL TANK

Figure 32. Skid Type Fuel Tank System

Refilling Procedures

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – make sure fuel cells are level with the

ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity. See Figure 33.

ALWAYS!

filling secondary internal tank.

fill trailer tank

first

with

#2 diesel fuel

, before

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

2. Trailer Fuel Tank First – The trailer fuel tank is the

place trailer on firm level ground before refueling

Figure 33. Only Fill on Level Ground

primary fuel tank and holds a larger capacity of fuel. The fuel in the trailer will be filtered and sent to the engine.

ALWAYS

fill trailer fuel tank (Figure 34) first.

Figure 34. Fuel Tank Filling Order

NOTE

ONLY! use

refueling.

Fuel from the secondary inner tank will eventually drain into the primary trailer tank.

#2 diesel fuel

when

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 41

DCA-800SSK — PRE-SETUP

3. NEVER overfill trailer fuel tank – It is important to

read the trailer fuel gauge when filling trailer fuel tank.

DO NOT wait for fuel to rise in filler neck. See Figure 35.

Figure 35. Full Trailer Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

4. Once the trailer tank is full, the

secondary inner tank

can be filled (See Figure 36). Notice how the trailer filler tube level rises when the internal tank is filled.

5. Figure 37 below reflects a full fuel system.

Figure 37. Full Fuel System

6. Fuel from the engine return line will drain into the secondary

internal fuel tank. This fuel will eventually drain into the primary trailer tank in order to return to the engine.

CAUTION - REFUELING SECONDARY FUEL TANK

It is recommended to only fill the internal secondary tank to 3/4 full in order to allow for fuel return, fuel expansion, and to avoid spillage. See Figure 38 for fuel expansion.

Figure 36. Filling Secondary Internal Fuel Tank

PAGE 42 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Figure 38. Fuel Expansion

DCA-800SSK— PRE-SETUP

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator

NOTE

may become coated with deposits and cooling efficiency will be reduced.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. See the engine manual for further details.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is

WARNING - BURN HAZARDS

dangerous, so clean only with the engine turned off and the

negative

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Komatsu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See

insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the

Komatsu Engine Owner's Manual.

Table 12 for engine and radiator, coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 39) when depressed with the thumb as shown below.

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

battery terminal disconnected.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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CAUTION - ROTATING PARTS

NEVER place hands near the belts or fan while the

generator set is running.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 43

DCA-800SSK— PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 40) are properly

connected to the battery terminals as shown below. The

RED

cable is connected to the positive terminal of the battery,

and the BLACK cable is connected to the negative terminal of the battery.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the Heat, RUN, or START position. ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

ignition

switch is in either the Pre-

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION - BATTERY SERVICING SAFETY

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 40. Battery Connections

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (

immediately

fuel

oil

) lines are defective replace them

PAGE 44 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GEN. START-UP PROCEDURE (MANUAL)

Before Starting

1. Place the

in the “OFF” position prior to starting the engine.

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

If applicable perform the following:

■

Apply commercial power to the internal battery charger receptacle (to ensure good starting) via commercial power. An external power cord will be required. This capability is an

option

■

Apply commercial power to the jacket water heater receptacle (not necessary for warm climates) via commercial power. An external power cord will be required. This capability is an

option

2. Connect the load to the

receptacles

connection points can be found on the output terminal panel. To gain access to the UVWO terminals or other

Generator and Control Panel

power receptacles, unlock the access cover and lift the door.

WARNING - STARTING THE GENERATOR

3. The UVWO terminals are protected by a plastic cover, remove this cover to gain access to the terminals.

NEVER!

manually start the engine with the

auxiliary

circuit breakers in the ON (closed) position.

main, GFCI

Tighten terminal nuts securely to prevent load wires from slipping out.

main, G.F.C.I.

Figure 42. Main, Aux. and GFCI

Circuit Breakers (OFF)

and

UVWO

aux.

circuit

terminals or

breakers (Figure 42)

as shown in Figure 43. These load

auxiliary

Steps 1 thru 19 are referenced for Engine Operating Panel up

NOTE

to S/N 3699247. See Figure 41 below. This panel has an

tion switch

Figure 41. Engine Operating Panel

Up To S/N 3699247

igni-

Figure 43. Load Connections

4. Close all engine enclosure doors (Figure 44).

Figure 44. Engine Enclosure Doors

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 45

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

6. When starting the generator in COLD weather conditions,

turn the

8. Place the

ignition key

Figure 46. Ignition Switch (Pre-Heat)

engine throttle lever

to the “PREHEAT ” position (Figure 46),

in the “LOW” position

(Figure 48). This lever is located on the generator control panel.

11. The generator's frequency meter (Figure 50) should be

displaying the 60 cycle output frequency in HERTZ.

Figure 50. Frequency Meter (Hz)

12. The generator's AC-voltmeter (Figure 51) will display the

generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 52) to increase or decrease the desired voltage.

Figure 51. AC Voltmeter

Figure 48. Engine Throttle Control

9. Turn the ignition key to the “START” position (Figure 49)

and listen for the engine to begin cranking. After the engine starts release the ignition key.

Figure 49. Engine Ignition Switch

10. Once the engine has started, let it run for 3-5 minutes, then turn the throttle handle control (Figure 48) to the “HIGH” position.

PAGE 46 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Figure 52. Voltage Adjust Control Knob

13. The ammeter (Figure 53) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 53. Ammeter (No Load)

DCA-800SSK — GENERATOR START-UP PROCEDURE (MANUAL)

14. The engine oil pressure gauge (Figure 47) will indicate the oil pressure (kg/ cm2) of the engine. Under normal

17. Place the

“ON” position (Figure 50).

operating conditions the oil pressure is approximately

kg/cm2

ENGINE OIL PRESSURE

Figure 47. Oil Pressure Gauge

15. The

coolant temperature gauge

(Figure 48) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit (

Green Zone

18. Observe the generator's ammeter (Figure 51) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current

WATER

TEMP

reading if a load is in use.

main, GFCI

Figure 50. Main, Aux. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers in the

Figure 48. Coolant Temperature Gauge

16. The

tachometer gauge

(Figure 49) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 49. Engine Tachometer Gauge

Figure 51. Ammeter (Load)

19. The generator will run until manually stopped or an abnormal condition occurs.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 47

DCA-800SSK — GENERATOR START-UP PROCEDURE (MANUAL)

BEFORE STARTING

Generator and Control Panel

WARNING - STARTING THE GENERATOR

NEVER!

manually start the engine with the

auxiliary

circuit breakers in the ON (closed) position.

Steps 20 thru 26 are referenced for Engine Operating Panel

NOTE

S/N 3699248~. See Figure 59 below. This panel does not have an ignition switch. It does have a “

pre-heat button

gine speed switch

used in conjunction with the MPEC unit.

main, GFCI

” and a “

en-

” that is

22. Place the engine speed switch in the “

LOW

” position

(Figure 62).

Figure 62. Engine Speed Switch (High)

23. Place the Auto-Off/Reset-Manual switch in the “

Manual”

position to start the engine (Figure 63). Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 63. Auto-Off/Reset-Manual Switch

24. Once the engine is warm and the engine is running properly, place the engine speed switch in the “

HIGH

”

position (Figure 64).

Figure 59. Engine Operating Panel

S/N 3699248~

20. Set the position.

battery ON/OFF switch

Figure 60. Battery ON/OFF Switch

(Figure 60) to the “ON”

25. Verify that the "Engine Running" status LED on the MPEC

unit (Figure 65) is "ON" (lit) after the engine has been started.

21. Press and hold the engine preheat button (Figure 59) until the preheat lamp is lit (ON).

Pre-Heat

Button

Pre-Heat

Lamp

26. Continue operating the generator as outlined in steps 11 thru 19 (pages 46-47).

Figure 60. Pre-Heat Button/ Lamp

Figure 64. Engine Speed Switch (High)

Figure 65. Engine Running LED (ON)

PAGE 48 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR SHUT-DOWN PROCEDURE (AUTO)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

The position when running in the

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

must install an

. Serious damage to the

licensed

isolation

set the switch in the proper position can result in damage to your generator when it turns on.

building’s electrical system may occur without this transfer switch.

CAUTION - BACKUP GENERATOR USE

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.

3. Set the engine speed switch (Figure 67) to the “High”

position.

WARNING - AUTO MODE MAINTENANCE

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

4. Place the Off/Manual/Auto switch (Figure 68) on the

MPEC unit to the AUTO position.

CAUTION - ENGINE SPEED SWITCH

Engine Speed Switch

NOTE

Figure 67. Engine Speed Switch (High)

must be set to the “High”

Auto-Start

When the generator is set in the “

AUTO ” mode, the generator will

automatically start

commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

mode. Failing to

in the event of

When starting generator in AUTO mode use the "

Manual

Start-up" procedure except where noted (see below).

1. Perform steps 1 through 4 in the (page 45) as outlined in the

2. Set the

battery ON/OFF switch

Before Starting

Manual Starting Procedure

section

(Figure 66) to the “ON”

position.

Figure 66. Battery ON/OFF Switch

Figure 68. Off/Manual Auto Switch (AUTO)

5. Continue operating the generator as outlined in steps 11 thru 19 (pages 46-47).

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 49

DCA-600SSK — GENERATOR SHUT-DOWN PROCEDURE

Engine Shutdown Ignition Key (Up to S/N 3699247)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers

Engine Shutdown Controller (S/N 3698617~)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers

(Figure 69) to the "OFF position".

2. Place the engine speed switch in the “

3. Let the engine cool by running it for 3-5 minutes with no

Figure 69. Main, Aux. and GFCI

Circuit Breakers (OFF)

4. Place the Auto-Off/Reset-Manual switch (Figure 74) to

2. Place the throttle control (Figure 70) in the “LOW” position.

as shown in Figure 67 to the "OFF position".

LOW

(Figure 73).

Figure 73. Engine Speed Switch (High)

load applied.

the

OFF/Reset

position.

” position

Figure 70. Engine Throttle Control

3. Let the engine cool by running it for 3-5 minutes with no load applied.

4. Place the ignition key (Figure 71) in the “STOP” position.

Figure 74. Off/Manual Auto Switch (AUTO)

5. Verify that the

"OFF" (not lit).

6. Remove all loads from the generator.

NEVER stop the engine suddenly except in an

Figure 71. Ignition Key Switch (STOP position)

emergency. DO NOT use the emergency stop switch as a method of shutting down the generator. This switch is

5. Remove all loads from the generator.

ONLY to be used in the event of an emergency.

Emergency Shutdown Procedure

1. PUSH inward the emergency stop button located on the

engine operating panel

(Figure 72) to turn off the generator in the event of an emergency. This button is located on either Engine Operating Panel.

NOTE

all

status LED on the MPEC display are

WARNING - EMERGENCY STOP SWITCH

To disengage the emergency stop function, pull the emergency stop button outward to its original position. This will allow

the generator to operate normally. Remember the generator will not start if the emergency stop button is engaged.

Figure 72. Emergency Stop Button

PAGE 50 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Use Table 14 shown below as a general checklist to be performed on a daily basis.

DCA-800SSK — MAINTENANCE

.41ELBAT

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

leveLnoitcetorP

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

tnalooCkcehCdnarotaidaRnaelC

tnemelEretliFriAecalpeR X

srH01

YLIAD

srH052 srH005 srH0001

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 51

smho

M3revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoH052taretlifleufecalpeR

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

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

Every

50 hours

element.

Outer Element:

1. Loosen wing bolt, remove dust cup, then remove wing nut and take out element.

2. Clean the inside of the body and cover using a damp cloth.

3. Blow dry with compressed air (0.69Mpa {7kgf.cm

99.4 PSI} maximum) against the side of the element along the pleats. Then blow dry against outside along the pleats, then against inside again.

4. Remove one seal each time the element is cleaned.

5. Replace the outer element after cleaning it 6 times or after one year. Replace the outer element if indicator is red even after cleaning it.

6. Check the inner cylinder element clamping nut for looseness, and retighten if necessary.

: If dust indicator is RED, clean the air cleaner

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

Removing Water from the Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally remove the drain cock and drain the contents. During cold weather, the greater the empty volume inside the tank, the easier it is for water to condense. This can be reduced by always keeping the tank as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system

according to the following procedure. To restart after running out of fuel, turn the key switch to the “START” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions, a clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber.

Cleaning the Fuel Strainer

7. If seal washer is damaged or the threads of wing nut are damaged, replace.

8. Remove evacuator valve and clean it with compressed air. Reinstall.

Inner element (if equipped)

1. Remove the cover and outer element, then remove the inner element.

2. Cover the air connector opening (outer side) with clean cloth or cloth tape.

3. Clean the inside of the body. Remove air connector opening protection.

4. Install a new inner cylinder element to the cylinder and tighten the nut.

5. Install element.

6. After replacing the element, press the button of the dust indicator to return the red piston to its original position.

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in diesel. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 30.

Check Electric Heater (If equipped)

Before starting in cold weather (once a year), please contact your Komatsu distributor for inspection. Remove electric heater from the engine intake manifold and check for disconnections or dirt. When checking or installing the electric heater, replace the gasket with a new part.

PAGE 52 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — MAINTENANCE

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Flushing Out Radiator and Changing Coolant

1. Stop the engine and allow to cool. Tighten valve of the

corrosion resistor (if equipped).

2. Turn water filer cap slowly and remove it.

3. Prepare a container to catch the coolant, then open drain

plug of the radiator or heat exchanger and drain plug of the engine, and drain the coolant.

4. After draining the coolant, close drain plugs and fill with

tap water.

5. When the water level is near the mouth of the water

filler, open drain plugs and start the engine, and run at low idling. Keep the engine running at low idling and flush the radiator for about 10 minutes.

6. Adjust the flow of the water flowing in and draining out

to ensure that the radiator is always full during the flushing operation. While flushing water through the system, watch carefully the water inlet hose does not come out of the radiator filler port.

7. After flushing, stop the engine, open drain plug and drain

the water, then close drain plugs.

8. After draining the water, flush the system with a flushing

agent. See instructions on flushing agent label.

9. After flushing, open drain plugs and drain out all the

water, then close drain plugs and add tap water so the water level is near the mouth of the water filler.

cool

when flushing out

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 level reaches near the water filer port, then tighten the radiator cap.

Changing Oil

1. Make sure the oil is cool before changing.

2. Set a container directly under the drain plug of the oil pan. Loosen the drain plug slowly.

3. Check the drained oil for excessive metal particles or foreign material. Contact the distributor if there is metal particles or foreign material.

4. Using a filter wrench, turn filter cartridge to the left to remove it. If the filter cartridge is filled with a large amount of oil, wait 10 minutes or so before removing. Make sure there is no old gasket stuck on the filter holder.

5. Tighten drain plug. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the packing and thread of the new filter cartridge with engine oil, then install it to the filter holder. Tighten until the gasket surface contacts the seal surface of the filter holder, then tighten it a further 3/4 to 1 turn.

6. Add engine oil through oil filler until the oil level is between the H and L marks on the dipstick.

7. Run the engine at idling for a short time, then stop the engine. Recheck the oil level and fill as necessary.

Replacing Fuel Filter

1. Set the container under the filter cartridge to catch fuel.

2. Using a filter wrench, turn the filter cartridge to the left to remove it.

10. When the water level is near the mouth of the water filler, open drain plugs and start the engine, run at low idling and continue to flush the system until clean water comes out. Adjust the flow of the water flowing in and draining out to ensure the radiator is always full during the flushing operation.

11. When clean water comes out, stop the engine, drain all the water, then close drain plugs.

12. Remove the corrosion resistor (if equipped) and open valve.

13. Supply water until it flows over the water filler.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 53

3. Clean the filter holder, fill the new filter cartridge with fuel, coat the packing surface of the filter cartridge with engine oil, then install the cartridge to the filter holder.

4. When installing, tighten until the packing surface contacts the seal surface of the filter holder then tighten a further 2/3 of a turn. If the filter cartridge is tighten too much, the packing will be damaged and will cause fuel leakage. Fuel leakage will occur if the filter cartridge is not tightened enough. Always tighten to the correct angle.

DCA-800SSK — MAINTENANCE

5. After replacing filter cartridge, loosen air bleed plug.

6. Loosen the knob of feed pump, and pump it up and down until no bubbles come out with the fuel from air bleed plug.

7. After bleeding the air, tighten air bleed plug, then push in the knob of feed pump and lock it in position.

8. Replace Corrosion resistor cartridge (if equipped)

9. Screw in valves at the top of the corrosion resistor.

10. Using a filter wrench, turn the cartridge to the left to remove it.

11. Coat the seal surface of the new cartridge with engine oil and install it to the filter holder.

12. Tighten until he packing surface contacts the seal surface of the filter holder, then tighten a further 2/3 of a turn.

13. Open valves.

Cleaning Breather Element

Generator Storage:

For storage of the generator for over 30 days, the following is required:



Fill the fuel tank completely. Treat with fuel stabilizer if necessary.



Completely drain oil from the crankcase and refill if necessary with fresh oil.



Clean the entire generator, internal and external.



Disconnect the negative terminals of the battery and cover it, or remove it from the generator and store it separately.



If the ambient temperature is expected to drop below 0oC, add antifreeze to the radiator.



Cover the generator set and store in a clean, dry place

Removal From Long Term Storage:



Apply oil to the engine valve and rocker arms, and examine the operating condition of the valves.

1. Loosen the clamp, then remove the hose and take out breather. Wipe off the dirt around the breather. Check the O-ring, and replace if necessary.

2. Wash the breather in diesel fuel or flushing oil, blow dry with compressed air, then reinstall it.

3. Inspect the hose and if there is any deteriorated oil stuck inside the hose. Replace hose if necessary.

Greasing

1. Using a grease pump, grease the fan hub (1 place) and tension pulley (2 places).



Remove the oil filler pipe from the turbocharger oil inlet port, add 0.5-1L (0.13-0.26 gal) of oil to the turbocharger, reinstall the oil filler pipe.



Change the oil in engine oil pan.



Replace all the filters.



Flush the inside of the cooling system.



Drain the water from the fuel tank and bleed the air from the fuel system.



If the engine has not been started for more than one year, contact your Komatsu distributor to have engine overhauled.

PAGE 54 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator is equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 75). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

jacket water heate

hot

climates there is no reason

cold

climates it is always a good

r and i

nternal

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

Figure 75. Battery Charger/Jacket Water

Heater Power Connections

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 55

DCA-800SSK — MAINTENANCE

Brakes

Trailer brakes should be inspected the operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

brakes more frequently.

Air Brake System

Air brakes use compressed air to make the brakes function. Air brakes are a good and safe way of stopping large and heavy vehicles. There are many components that make up an air-brake system, such as the air compressor, air compressor governor, air storage tanks and air tank drains. These components need to be maintained by

trained technicians

S-Cam Brakes

first 200 miles

qualified

and

When the brake pedal is pushed, air is let into each brake chamber (Figure 76). Air Pressure pushes the rod out, moving the slack adjuster, thus twisting the brake cam shaft. This

Brake Drums (or discs), Linings, and Hoses

turns the s-cam (so called because it is shaped like the letter "S").

Brake drums or discs must not have cracks longer than one half the width of the friction area. Linings must not be loose,

The s-cam forces the brake shoes away from one another and presses them against the inside of the brake drum. When the brake pedal has been released, the s-cam rotates back and a spring pulls the brake shoes away from the drum,

soaked with oil or grease or be dangerously thin. Mechanical parts must be in place, not broken or missing. Check that all air hoses connected to the brake chambers are not worn or cut due to rubbing.

letting the wheels roll freely.

Air Leaks

Air Tank Drains

Always check for brake air leaks before towing the trailer.

Compressed air usually has some water in it which is for the air brake system. Water can freeze in cold weather

bad

NEVER tow the trailer with an brake air leak problem. The

possibility exists of brake failure.

and thus cause brake failure. The water tends to collect in the bottom of the air tank.

to remove water from the air tank

Daily air tank drainage is required

motpmyS esuaCelbissoP noituloS

Use Table 15 as a basic

NOTE

troubleshooting guide when brake problems occur.

ediSenO

Figure 76. Hydraulic Brake Components

gnitoohselbuorTekarBriA.51elbaT

?deknikronekorbenilekarBriA.ecalperroriapeR

sekarBoN

akcalS.yltcerroctsujdA

otlluPsekarBrosekarBkaeW

sekarBgnikcoL?nekorbrotneb,esoolstnenopmocekarB.stnenopmocecalpe

sekarBysioN?dezalggninildnasmurDdnag

sekarBgniggarD

?gninilnroW.gninilecalpeR

?tcerrocnitnemtsujd

?dezalggninilekarB.ecalperrohsinrubeR

liarT.thgiewtcerroC

?dedaolrevore

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserperiT.yllauqeseritllaetalfn

?elxaemasehtnodehctamnuseriT.serithctaM

?dnuor-fo-tuosmurdekarB.ecalpeR

?dezalggninilekarB.gninilekarbecalpeR

tonrotcerrocnissenkcihtgninilekarB

?yltcerrocdetsujda

?detacirbulsgnittifkreZ.sgnittifkrezetacirbuL

ninilekarbecalpeR

.murd

ohswenllatsnI

.sgninildnase

PAGE 56 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK —TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

CAUTION - EYESIGHT HAZARD

ALWAYS

removing or installing force fitted parts. Failure to comply may result in serious injury.

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are pressure weekly during use to insure the maximum tire life and tread wear.

wear safety glasses when

CAUTION - REPAIRING TRAILER WHEELS

hot!

. Check inflation

Suspension

The

leaf suspension

(Figure 77) should be visually inspected for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components as detailed in Table 17.

springs and associated components

every 6,000

miles

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

NOTE

ALWAYS

when removing or installing force fitted parts. Failure to comply may result in serious injury.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 57

wear safety glasses

Figure 77. Major Suspension Components

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-800SSK —TRAILER MAINTENANCE

stnemeriuqeReuqroTnoisnepsuS.71elbaT

SHACKLE BOLT SPRING EYE BOLT

SHOULDER TYPE SHACKLE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY. LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT

-BOLT ASSEMBLY.

05-XAM03-NIM

Lug Nut Torque Requirements

It is extremely important 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. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 78. DO NOT

torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

SBL-TF

ssaPdnoceS

SBL-TF

PAGE 58 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

ssaPdrihT

SBL-TF

Figure 78. Wheel Lug Nuts Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

NOTE

Use a

torque wrench

to tighten

lug nuts.

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 59

DCA-800SSK — TRAILER-WIRING DIAGRAM

Figure 80. Trailer Wiring Diagram (7-Pin)

PAGE 60 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR WIRING DIAGRAM

Figure 81. Generator Wiring Diagram

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 61

DCA-800SSK — GENERATOR WIRING DIAGRAM (MAIN BREAKER)

Figure 82. Main Circuit Breaker Wiring Diagram

PAGE 62 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENGINE WIRING DIAGRAM

Figure 83. Engine Wiring Diagram

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 63

DCA-800SSK — ENGINE WIRING DIAGRAM

Figure 84. Engine Wiring Diagram(Continued)

PAGE 64 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

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

DCA-600SSK — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 (Engine Troubleshooting) as a basic guideline for troubleshooting the engine. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

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?erutarepmet

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?tungniniaterepip

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?nrowtfahsmacleuF .ecalpeR

?rednilyc

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?degrahcsidyrettaB .yrettabegrahC

noitcejniesooloteudkaelleuF

?gnimitnoitcejnitcerrocnI .tsujdA

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

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?detcennocsidgniriW .gniriwtcennoC

PAGE 66 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.02ELBAT

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.tunnethgiT

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.redlohelzzon

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 67

DCA-800SSK — TROUBLESHOOTING (GENERATOR/ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 21 (Generator Troubleshooting) as a basic guideline for troubleshooting the generator. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.12ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

deppirTrekaerBtiucriC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?daolnitiucriCtrohS .riaperdnadaolkcehC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 68 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — TROUBLESHOOTING (MPEC)

Use Table 22 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the MPEC. If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.22ELBAT

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

thgilerusserpliowoL

.nosi

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

.nosi

tnaloochgiH

thgilleveltnaloocwo

.nosithgilerutrepmet

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yretta

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytlu

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplio

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaida

rhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

ecalpeR

begrahc/ecalpeR

afrosteksagriaper/ecalpeR

?leuFwolrooN.levelleuflliF

evO

ssoL

.no

.nosithgilknarcr

?detarbilacebotsdeenrellortnoC.relaedotrefeR

psenigneMPR.MPRtsujdA

.nosithgildeepsrevO

tnocronrevoG .rellortnocronrevogtsujdA

ro)s(thgilUPMfo

?hgihootdee

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellor

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipcitengaM .pukcipcitengamnaelC

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 69

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

QTY. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁed in the “Remarks” Column.

Serial Number Break — Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use — Indicates that the part is used only with the speciﬁc model number or model number variant listed. It can also be used to show a part is NOT used on a speciﬁc model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” — Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

PAGE 70 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — SUGGESTED SPARE PARTS

DCA-800SSK W/KOMATSU SA12V140 DIESEL ENGINE 1 TO 3 UNITS

1 to 3 Units

Qty. P/N Description

6 ....... 5610262520...................... AIR FILTER, INNER

12 ..... 5610262530...................... AIR FILTER, OUTER

12 ..... 6003117111...................... FUEL FILTER

24 ..... 6002111231...................... OIL FILTER

6 ....... 6004111171...................... CARTRIDGE, CORROSION RESISTOR

6 ....... 0810105400...................... FUEL FILTER, FUEL TANK

1 ....... 0601810575...................... PILOT LAMP, ENGINE TROUBLE

1 ....... 0601810576...................... PILOT LAMP, ENGINE TROUBLE

1 ....... 0412222274...................... FAN BELT, ENGINE (SET OF 3)

2 ....... 6008155390...................... SWITCH, STARTER ............................................. TO S/N 3699247

6 .......615 ................................... KEY SET, STARTER SWITCH (2) ....................... TO S/N 3699247

1 ....... 6215619720...................... RADIATOR HOSE (UPPER)

1 ....... 6215619750...................... RADIATOR HOSE (LOWER)

1 ....... 0605505030...................... FUEL CAP, TANK W/KEY

1 ....... 0601850590...................... KEY, FUEL TANK CAP

1 ....... 0601820625...................... AUTOMATIC VOLTAGE REGULATOR

1 ....... 7520150704...................... CIRCUIT BREAKER, AT25 .................................. UP TO S/N 3706720

1 ....... 0601840073...................... RHEOSTAT, (VOLTAGE REGULATOR)

2 ....... 0601840121...................... KNOB, RHEOSTAT

1 ....... 0601810072...................... PILOT LAMP

2 ....... 0601810261...................... BULB, PILOT LAMP

1 ....... 0602122200...................... UNIT, OIL PRESSURE

1 ....... 0602123206...................... UNIT, WATER TEMPERATURE

1 ....... 0601807515...................... CIRCUIT BREAKER, S8V 2500A ........................ S/N 3706721~

1 ....... ECU9988N600/800 ...........ECU, ENGINE CONTROLLER ... S/N 3699248~

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 71

GENERATOR ASSY.

DCA-800SSK — GENERATOR ASSY.

PAGE 72 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5110000102 ROTOR ASSY. .......................................... 1 ......... INCLUDE ITEMS W/

1-1

1-2*0601842366 RESISTOR ............................................... 4 .........SMRK 80W 50K OHM

1-3*8171020004 INSULATOR WASHER 6 1-4*8171020504 INSULATOR WASHER 6 1-5*C5111100002 FAN 6 1-6*C5163400003 COUPLING RING 1 1-7*0010312025 HEX. HEAD BOLT 1 1-7*0042512000 LOCK WASHER 2 1-8*C5163100104 COUPLING DISK ASSY. 2 1-9*C5163200004 WASHER, COUPLING HUB 1 1-10*C5111300003 BALANCING PLATE 1 1-11*0012724060 HEX. HEAD BOLT 10 1-12*0042524000 LOCK WASHER 10 1-13*8461026023 SET PLATE, RECTIFIER 1

1-14*0601823282 RECTIFIER .............................................. 2 ......... RM50TC-24

1-15*0018205020 HEX. SOCKET HEAD CAP SCREW 4 1-15*0040005000 LOCK WASHER 4 1-15*0041205000 PLAIN WASHER 4 1-16*0010112020 HEX. HEAD BOLT 6 1-16*0040012000 LOCK WASHER 6 1-17*060100020 BALANCING WEIGHT KIT 1 1-18*C5111500003 BEARING FLANGE 1 1-19*0070106322 BEARING 1 1-20*0080000110 SNAP RING 1 1-21*C5153300104 GASKET, BEARING 1 2 0012116065 HEX. HEAD BOLT 10 2 0042516000 LOCK WASHER 10 3 C5130000003 STRATOR ASSY. 1 3-1 C5131200404 CLAMPER 4 3-2 C5131200014 CLAMPER 4 3-3 C5131200504 CLAMPER 2 3-4 0016310090 HEX. HEAD BOLT 4 3-4 0030010000 HEX. NUT 4 3-4 0040010000 LOCK WASHER 8 3-4 0041210000 PLAIN WASHER 4 3-5 0017110020 HEX. HEAD BOLT 8

FIELD ASSY. 1

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 73

GENERATOR ASSY.

DCA-800SSK — GENERATOR ASSY.

PAGE 74 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

4 C5153000002 END BRACKET 1 5 C4137000003 FIELD ASSY., EXCITER 1 6 0012110075 HEX. HEAD BOLT 6 6 0042610000 LOCK WASHER 6 6 0041210000 PLAIN WASHER 6 7 0845044904 GROMMET 1 8 0016316045 HEX. HEAD BOLT 8 8 0040016000 LOCK WASHER 8 8 0041216000 PLAIN WASHER 8 9 C5153300003 COVER, BEARING 1 10 C5153300104 GASKET, BEARING 1 11 0016308095 HEX. HEAD BOLT 3 11 0040008000 LOCK WASHER 3 11 0041208000 PLAIN WASHER 3 12 0010110016 HEX. HEAD BOLT 1 13 0803000104 PACKING 1 14 8461335004 BRACKET, COVER 1 15 C5131300103 COVER, STATOR 1 16 0017106012 HEX. HEAD BOLT 4 17 0017106050 HEX. HEAD BOLT 2 18 8461333003 COVER, EXCITER 1 19 0017106012 HEX. HEAD BOLT 2 20 0012112040 HEX. HEAD BOLT 16 20 0042512000 LOCK WASHER 16 21 C5131300003 COVER, FAN 1 22 0017106050 HEX. HEAD BOLT 1 23 0605000012 RUBBER SUSPENSION 4 24 0030020000 HEX. NUT 8 24 0040020000 LOCK WASHER 8

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 75

CONTROL PANEL ASSY.

DCA-800SSK — CONTROL PANEL ASSY.

PAGE 76 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5224000503 CONTROL PANEL 1 2 C5224000403 CONTROL PANEL 1 3 0605011211 PIN 4

4 0601810476 OFF LAMP, CIRCUIT BREAKER ............ 1.......APN133-G

4 0601810235 BULB ....................................................... 1....... LS-3

5 0601810467 ON LAMP, CIRCUIT BREAKER .............. 1....... APN133-R

5 0601810235 BULB ....................................................... 1....... LS-3

6 0601830498 OFF SWITCH, CIRCUIT BREAKER ....... 1.......AH30-FR10

7 0601831224 ON SWITCH, CIRCUIT BREAKER ......... 1....... AH30-FB10

8 0601830780 THROTTLE LEVER ................................. 1 ....... ARNS1-2020 UP TO S/N 3699247

8 0601850267 GROMMET .............................................. 1....... S/N 3693886~

9 0601800480 FREQUENCY METER ............................ 1....... PAK-100 0~1500A 0~3000A

10 0601800795 AC AMMETER ........................................ 1 .......SL-2 AS

11 0601801040 CHANGE-OVER SWITCH, AMMETER ... 1....... PCK-100 0~6000V

12 0601800252 AC VOLTMETER ..................................... 1....... SL-2 VS

13 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1....... SP-132DC 220V

14 0601810072 PILOT LAMP ........................................... 1 ....... CT-13W

14 0601810261 BULB 1

15 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ..... 1....... RA20A2SE102BJ 2W 1K OHMS

16 0601840121 KNOB 1

17 ECU9988N600/800 ENGINE CONTROLLER.......................... 1 .......S/N 3699248~

17 0602202471 SEALED CABLE ..................................... 1.......S/N 3699248 ~REPL.060220254+0601827395

17 DYNT11200 SPEED SENSOR .................................... 1 ....... S/N 3699248~ REPLACES 0602120498

18 0601831340 SWITCH .................................................. 1....... S/N 3692434 TO 3698625

18 0601830765 SWITCH, S303T ...................................... 1....... S/N 3698626~

19 0601810161 PANEL LIGHT 1 19 0601810214 BULB 1 20 0207004000 HEX. NUT 2 21 0601830710 SWITCH, PANEL LIGHT 1 22 C9221100004 HEX. HEAD BOLT 4 22 0040008000 LOCK WASHER 4 22 0041208000 PLAIN WASHER 4 22 0080200007 SNAP RING 4

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 77

CONTROL BOX ASSY.

DCA-800SSK — CONTROL BOX ASSY.

PAGE 78 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5214000002 CONTROL BOX ........................................ 1 ......... S/N 3692434 TO S/N 3706720

1 C52140100502 CONTROL BOX ........................................ 1 .........S/N 3706721~

2 0601806166 CURRENT TRANSFORMER, AMMETER 3 ......... CW040LM 1500/5A

3 0017108020 HEX. HEAD BOLT 6

4 C5261500603 SET PANEL, ELECTRIC PARTS.............. 1 ......... UP TO S/N 3698625

4 C5252500303 SET PANEL, ELECTRIC PARTS.............. 1 ......... S/N 3698626~

5 C5261500703 SET PANEL, ELECTRIC PARTS.............. 1 ......... UP TO S/N 3698625

5 C5262500203 SET PANEL, ELECTRIC PARTS.............. 1 ......... S/N 3698626~

6 0017108020 HEX. HEAD BOLT 14

7 0601820625 AUTOMATIC VOLTAGE REGULATOR ...... 1 .........NTA-5A-2T

8 0027105016 MACHINE SCREW 4

9 0601820892 OVER CURRENT RELAY ......................... 1 ......... TH-N20 HZKP 3.6A

10 0027104016 MACHINE SCREW 2

11 0601815020 TERMINAL BOARD ................................. 1 ......... UP TO 3698625

11 0601815402 TERMINAL BOARD ................................. 1 ......... S/N 3698626~

12 0027104020 MACHINE SCREW 2 13 C5352800003 BRACKET, CONTROLLER 1 14 0017106016 HEX. HEAD BOLT 6

15 6215819121 CONTROLLER ......................................... 1 .........REPLACES 0602202553

16 0207006000 HEX. NUT 4

17 Z0110000904 RESISTOR UNIT ...................................... 2 .........1/4W 560 OHMS x4

18 0030006000 HEX. NUT 2 19 0027105020 MACHINE SCREW 2 20 C5352800104 BRACKET 1 21 0017105016 HEX. HEAD BOLT 4

22 0601810575 PILOT LAMP, ENGINE TROUBLE ........... 1 ......... KRE-108-4R DC24V

23 0601810576 PILOT LAMP, ENGINE TROUBLE ........... 1 ......... KRE-108-4G DC24V

24 0601831205 RESET SWITCH, PILOT LAMP ............... 1 .........SB-221N/0

25 0601840009 RHEOSTAT (DROOP & IDLE SPEED ...... 2 ......... RA20A2SE502BJ 2W 5K OHMS

CONTROLLER)

26 0601831323 SWITCH, OVER SPEED TEST ................ 1 .........S-1AL

27 0601815802 TERMINAL BOARD 1 28 0027104020 MACHINE SCREW 2 29 0601802133 FUSE (LEFT SIDE), 5A 1 29 0601802149 FUSE (RIGHT SIDE), 10A 1 29 0601802211 HOLDER, FUSE 1 30 0021004020 MACHINE SCREW 2

30 0021003020 MACHINE SCREW ................................... 2 ......... S/N 3702703~

31 0601823706 RELAY ...................................................... 1 ......... HE1A DC24V AHE1212

32 0027104016 MACHINE SCREW 2

33 0601823732 RELAY ...................................................... 1 ......... LY2 DC24V

33 PTF08A SOCKET .................................................. 1 ......... REPLACES 0601823109

33 PYCA1 HOLDER ................................................... 1 .........REPLACES 0601824400

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 79

CONTROL BOX ASSY.

DCA-800SSK — CONTROL BOX ASSY.

PAGE 80 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

34 0601823757 RELAY, MY2DC24V 1 UPTO S/N 3698625 34 0601823143 SOCKET, PYF08A 1 UPTO S/N 3698625 34 PYCA1 HOLDER 1 REPLACES 0601824400 34 0601823732 RELAY, LY2DC24V 1 UP TO S/N 3699247 34 0601827655 RELAY, LY2DC24V 1 S/N 3699248~ 34 PTF08A SOCKET 1 S/N 3698626~ REPL. 0601823109

35 0601823759 RELAY ...................................................... 2 ......... MY4 DC24V

35 0601823146 SOCKET 2 35 0601824400 HOLDER 2 36 0027104016 MACHINE SCREW 8

37 0602201911 UNIT, BATTERY SENSOR ....................... 1 ......... C7038A-00-00

38 0017106016 HEX. HEAD BOLT 1

39 7520150704 CIRCUIT BREAKER, AT25 ....................... 1 .........UP TO S/N 3706720

39 0601807515 CIRCUIT BREAKER, S8V2500A .............. 1 ......... S/N 3706721~

40 0017112030 HEX. HEAD BOLT .................................... 4 ......... UP TO 3706720

40 0010308050 HEX. HEAD BOLT .................................... 8 ......... S/N 3706721~

40 0042508000 SPRING WASHER ................................... 8 ......... S/N 3706721~

40 0041208000 PLAIN WASHER ....................................... 8 ......... S/N 3706721~

41 7521861303 CHANGE-OVER BOARD, VOLTAGE 1 42 C5277000004 CHANGE TERMINAL 10 43 0017108035 HEX. HEAD BOLT 20 44 C5277200004 TERMINAL PLATE 10 45 C5277300004 CHANGE PLATE 6 46 0801832504 HEX. HEAD BOLT 20 47 0040020000 LOCK WASHER 20 48 0041420000 PLAIN WASHER 20 49 0010110040 HEX. HEAD BOLT 4 49 0040010000 LOCK WASHER 4 49 0041210000 PLAIN WASHER 4 50 3871824004 STOPPER, CONTROL PANEL 2 51 0041206000 PLAIN WASHER 2 52 0605010502 SNAP PIN 2

53 7521828704 FLOOR PANEL ......................................... 1 .........UP TO S/N 3706720

54 0017106016 HEX. HEAD BOLT .................................... 4 ......... UP TO S/N 3706720

55 7521814703 COVER, CONTROL BOX ......................... 1 .........UP TO 3706720

55 C5214500003 COVER, CONTROL BOX ......................... 1 .........S/N 3706721~

56 0017106016 HEX. HEAD BOLT 14 57 7521826704 SIDE PANEL, CONTROL BOX 2 58 0017106016 HEX. HEAD BOLT 24 59 7521827603 PANEL, CONTROL BOX 1 60 0017106016 HEX. HEAD BOLT 15 61 7521811904 BRACKET 2 62 0017110025 HEX. HEAD BOLT 4 63 0017108020 HEX. HEAD BOLT 3 64 0017110030 HEX. HEAD BOLT 4 64 0207010000 HEX. NUT 4

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 81

ENGINE AND RADIATOR ASSY.

DCA-800SSK — ENGINE AND RADIATOR ASSY.

PAGE 82 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5924200024 ENGINE, KOMATSU SA12V140 .............. 1 ......... TO S/N 3700267

1 C5924200024 ENGINE, KOMATSU SA12V140E ............ 1 .........S/N 3700268~

2 6002111231 CARTRIDGE, OIL FILTER ....................... 4 ......... REPLACES 0602041146

3 6003117111 CARTRIDGE, FUEL FILTER .................... 2 ......... REPLACES 0602042157

4 6004111171 CARTRIDGE, CORROSION RESISTOR.. 2 ......... REPLACES 0602045144

5 C5304200004 ENGINE FOOT 1 6 C5304200104 ENGINE FOOT 2 7 0010120100 HEX. HEAD BOLT 2 8 0010120060 HEX. HEAD BOLT 6 9 0030020000 HEX. NUT 6 10 0040020000 LOCK WASHER 6 11 0041220000 PLAIN WASHER 6 12 0605000012 RUBBER SUSPENSION 5 13 0030020000 HEX. NUT 10 14 0040020000 LOCK WASHER 10

15 6215619711 RADIATOR ................................................ 1 .........REPLACES 0602011987

16 6995621350 RUBBER SHEET...................................... 2 ......... REPLACES 0605000098

17 0010118080 HEX. HEAD BOLT 8 18 0030018000 HEX. NUT 8 19 0040018000 LOCK WASHER 8 20 0041218000 PLAIN WASHER 8 21 C5311100004 BRACKET, RADIATOR 2 22 0017112025 HEX. HEAD BOLT 4 23 0017110025 HEX. HEAD BOLT 4

24 6215619720 RADIATOR HOSE, UPPER ...................... 2 ......... REPLACES 0602014595

25 6215619750 RADIATOR HOSE, LOWER ..................... 1 .........REPLACES 0602014643

26 6215619730 RADIATOR PIPE ...................................... 1 .........REPLACES 0602013369

27 0726120914 RADIATOR HOSE .................................... 2 .........REPLACES 0602014596

28 0726122620 RADIATOR HOSE .................................... 1 .........REPLACES 0602014597

29 0728100909 HOSE BAND ............................................ 8 ......... REPLACES 0602014056

30 0728101159 HOSE BAND ............................................ 4 ......... REPLACES 0602014356

31 0728001920 HOSE BAND ............................................ 4 ......... REPLACES 0602014058

32 0728100419 HOSE BAND ............................................ 2 ......... REPLACES 0602014057

33 6215619740 BRACKET ................................................ 1 ......... REPLACES 0602013860

34 0728328973 U BOLT ..................................................... 1 ......... REPLACES 0602011548

35 0159901214 NUT .......................................................... 2 .........REPLACES 0602011650

36 6152817500 AIR CLEANER, ASSY. ............................. 2 ......... REPLACES 0602046254

36 5610262520 ELEMENT, AIR CLEANER, INNER .......... 2 ......... REPLACES 0602046348

36 5610262530 ELEMENT, AIR CLEANER, OUTER ........ 2 .........REPLACES 0602046348

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 83

ENGINE AND RADIATOR ASSY.

DCA-800SSK — ENGINE AND RADIATOR ASSY.

PAGE 84 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

37 6001813960 CAP, AIR CLEANER ................................ 2 .........REPLACES 0602040752

38 6215114410 BRACKET, AIR CLEANER ....................... 2 .........REPLACES 0602040950

39 6151119970 BAND, AIR CLEANER .............................. 2 ......... REPLACES 0602040560

40 6643114641 BOLT ........................................................ 2 .........REPLACES 0602011547

41 6215114470 HOSE, AIR CLEANER ............................. 1 .........REPLACES 0602040353

42 6215114480 HOSE, AIR CLEANER ............................. 1 .........REPLACES 0602040354

43 1252151H1 HOSE BAND ............................................ 2 ......... REPLACES 0602040450

44 0728900170 HOSE BAND ............................................ 2 ......... REPLACES 0602040451

45 C5374200103 BRACKET, AIR CLEANER 1 46 C5374200003 BRACKET, AIR CLEANER 1 47 0017110030 HEX. HEAD BOLT 8 48 0017110030 HEX. HEAD BOLT 8 49 0207010000 HEX. NUT 8 50 0193602800 HOSE 1 51 0605515170 HOSE CLIP 1 52 0194201500 HOSE 1 53 0605515019 HOSE BAND 1

54 0728100549 BREATHER HOSE ................................... 1 .........UP TO S/N 3692433 REPL. 0602014069

54 7700751310 BREATHER HOSE ................................... 1 ......... S/N 3692434~

55 0728100549 HOSE BAND ............................................ 2 ......... REPLACES 0602014069

56 C5358300204 CLAMPER 1 57 0412222274 FAN BELT, ENGINE (SET OF 3) 1

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 85

OIL DRAIN ASSY.

DCA-800SSK — OIL DRAIN ASSY.

PAGE 86 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OIL DRAIN ASSY.

OIL DRAIN ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0602023160 PUMP ............................................................. 1 .......... GM-2524H

2 0017108040 HEX. HEAD BOLT 4 2 0207008000 HEX. NUT 4 3 0131710060 BUSHING, 1 x 1/2 1 4 0131708060 BUSHING 3/4 x 1/2 1 5 0130206000 STREET ELBOW, 1/2 3 6 0602022202 HOSE JOINT 4 7 3502054124 DRAIN JOINT 1 8 0802024004 PACKING 1 9 0191602700 HOSE 1 10 0191601600 HOSE 1 11 0605515134 HOSE BAND 4 12 0132006000 PLUG, 1/2 1

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 87

ENGINE OPERATING PANEL ASSY.

DCA-800SSK — ENGINE OPERATING PANEL ASSY.

PAGE 88 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5484000002 SUPPORT LEG 1 2 0017112045 HEX. HEAD BOLT 4 2 0030012000 HEX. NUT 4 2 0041212000 PLAIN WASHER 4 3 0017110025 HEX. HEAD BOLT 2 3 0207010000 HEX. NUT 2

4 C5352100203 OPERATING PANEL .................................... 1 ..... UP TO S/N 3698625

4 C5352100213 OPERATING PANEL .................................... 1 ..... S/N 3698626~

5 0017108020 HEX. HEAD BOLT 4 6 0017108020 HEX. HEAD BOLT 3 7 8085182004 RUBBER COVER 3 8 8085183004 SET FRAME, RUBBER COVER 3 9 0017106020 HEX. HEAD BOLT 18

10 0602101016 BATTERY SWITCH ...................................... 1 ..... 0315251001

11 7522258304 BRACKET, BATTERY SWITCH 2 12 0017106030 HEX. HEAD BOLT 4 12 0207006000 HEX. NUT 4 13 0025006016 MACHINE SCREW 4 13 0042306000 LOCK WASHER 4 13 0042506000 PLAIN WASHER 4

14 6008155390 STARTER SWITCH ...................................... 1 ..... UP TO S/N3699247 REPL. 0602100049

14A 615 KEY, STARTER SWITCH ............................. 1 ..... UP TO S/N3699247

15 0806410000 EMERGENCY STOP BUTTON ................... 1 ..... REPLACES 0602104045

16 6008153730 PREHEAT INDICATOR ................................ 1 ..... REPLACES 0602102055

17 0602120054 TACHOMETER ............................................. 1 ..... 25000-KX4110

18 0602120173 CABLE, TACHOMETER ............................... 1 ..... 62500-KA4110 L=4000

19 0602122060 OIL PRESSURE GAUGE ............................. 1 ..... 4200-KX1410

20 0602122200 UNIT, OIL PRESSURE ................................. 1 ..... 53000-AC0101

21 0602123061 WATER TEMPERATURE GAUGE ............... 1 ..... 40000-KX0910

22 0602123206 UNIT, WATER TEMPERATURE ................... 1 ..... 51400-KS0600

23 0602121052 CHARGING AMMETER ............................... 1 ..... 43000-KV0300

24 0602125060 FUEL GAUGE ............................................... 1 ..... 41000-KW0110

25 0602040692 INDICATOR, AIR CLEANER ........................ 2 ..... RBX00-2254

26 6203306104 SOCKET 2

27 0603301000 ELBOW UNION ............................................ 2 ..... UP TO S/N 3702700

27 0603301030 ELBOW UNION ............................................ 2 ..... S/N 3702701~

28 0603300000 HALF UNION ................................................ 2 ..... UP TO S/N 3702700

28 0603300040 HALF UNION ................................................ 2 ..... S/N 3702701~

29 0603302000

29 0603302020 SLEEVE ........................................................ 4 ..... S/N 3702701~

30 0603303000 NUT ............................................................... 4 ..... UP TO S/N 3702700

30 0603303030 NUT ............................................................... 4 ..... S/N 3702701~

31 0190002900 NYLON PIPE ................................................. 2 ..... UP TO S/N 3702700

31 0190302500 NYLON PIPE, LEFT SIDE ............................ 1 ..... S/N 3702701~

31 0190302800 NYLON PIPE, RIGHT SIDE .......................... 1 ..... S/N 3702701~

32 0602115008 LED MODULE ............................................... 1 ..... V33676A

33 0602103091 ALARM LAMP, OIL FILTER .......................... 1 ..... REPLACES 0602103090

33 0601810244 BULB 1

34 0601830710 ENGINE SPEED SWITCH ............................ 1 ..... S-301T

35 0601850267 GROMMET 1

36 0601830448 PREHEAT BUTTON, AH25FB101 ............... 1 ..... S/N3699248~

SLEEVE ........................................................ 4 ..... UP TO S/N 3702700

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 89

OUTPUT TERMINAL ASSY.

DCA-800SSK — OUTPUT TERMINAL ASSY.

PAGE 90 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5231700003 SET BOARD, OUTPUT TERMINAL 1 2 7521860504 OUTPUT TERMINAL 4 3 7521850504 BRACKET, OUTPUT TERMINAL 4 4 0010112040 HEX. HEAD BOLT 8 4 0030012000 HEX. NUT 8 4 0040012000 LOCK WASHER 8 4 0041212000 PLAIN WASHER 16 5 0010112060 HEX. HEAD BOLT 8 5 0030012000 HEX. NUT 8 5 0040012000 LOCK WASHER 8 5 0041212000 PLAIN WASHER 16 6 0010112040 HEX. HEAD BOLT 24 6 0030012000 HEX. NUT 24 6 0040012000 LOCK WASHER 24 6 0041212000 PLAIN WASHER 48 7 C5234000004 TERMINAL 1 8 0801830904 HEX. HEAD BOLT 1 9 0039320000 HEX. NUT 2 10 0040020000 LOCK WASHER 3 11 0041420000 PLAIN WASHER 5 12 0019112060 HEX. HEAD BOLT 6 12 0042312000 LOCK WASHER 6 12 0042412000 PLAIN WASHER 6 13 0601850275 GROMMET 1 14 0601815324 TERMINAL BOARD 1 15 0027104020 MACHINE SCREW 2 16 C4237101304 COVER, OUTPUT TERMINAL 1 17 7971867114 RUBBER SHEET 1 18 7521865804 SET PLATE, RUBBER SHEET 1 19 0019106020 HEX. HEAD BOLT 5 19 0042306000 LOCK WASHER 5 19 0442406000 PLAIN WASHER 5 20 0605010660 KNOB 2 21 0207006000 HEX. NUT 2 22 0010112045 HEX. HEAD BOLT 4 23 0041212000 PLAIN WASHER 4 24 0805009804 STAY RUBBER 4

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 91

OUTPUT TERMINAL ASSY.

DCA-800SSK — OUTPUT TERMINAL ASSY.

PAGE 92 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

25 0030012000 HEX. NUT 4 26 7521865603 STOPPER 1 27 0010108030 HEX. HEAD BOLT 1 27 0030008000 HEX. NUT 1 27 0041208000 PLAIN WASHER 2 28 C4237100504 COVER 1 29 0017108020 HEX. HEAD BOLT 5

30 0601805840 CIRCUIT BREAKER, KM-52 265V 50A ....... 3 ......... S/N 3692434 TO 3706720

30 0601808804 CIRCUIT BREAKER, QOU 250B 50A ............ 1 ......... S/N 3706721~

31 C5261600004 BRACKET, CIRCUIT BREAKER .................... 1 .........INCL. ITEMS W/

31 G5261600204 BRACKET, CIRCUIT BREAKER .................... 1 ......... INCLUDES ITEMS W/# S/N 3706721~

32# 0221200110 RUBBER CUSHION ....................................... 1 .........S/N 3706721~

33 0017106030 HEX. HEAD BOLT 2

34 0601811034 RECEPTACLE................................................ 3 ......... REPLACES 0601812565 & 0601812535

35 0027104015 MACHINE SCREW 6 35 0030004000 HEX. NUT 6 35 0041204000 PLAIN WASHER 6 36 C4237101203 COVER 1

37 0601851780 GROMMET .................................................... 1 ......... S/N 3700699~

0223300150 RUBBER CUSHION ....................................... 1 .........UP TO S/N 3706720

UPTO S/N 3706720

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 93

BATTERY ASSY.

DCA-800SSK — BATTERY ASSY.

PAGE 94 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0168719052 BATTERY 4 2 0805018904 BATTERY SHEET 4 3 0805006404 BATTERY BAND 2 4 0805006504 BATTERY BOLT 4 5 0037808000 WING NUT 4 6 0040008000 LOCK WASHER 4 7 0041208000 PLAIN WASHER 4 8 C5347800104 BATTERY CABLE 1 9 C5347800004 BATTERY CABLE 1 10 7522280904 BATTERY CABLE 2 11 C5347600104 BATTERY CABLE 1 12 C5347400004 EARTH CABLE 1 13 0347010030 HEX. HEAD BOLT 8 14 0208110000 HEX. NUT 8 15 0845040114 TERMINAL CAP (+) 4 16 0845041004 TERMINAL CAP (-) 4 17 0602220205 BATTERY SENSOR 1 18 C5347600004 BATTERY CABLE 2

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 95

MUFFLER ASSY.

DCA-800SSK — MUFFLER ASSY.

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

DCA-800SSK — MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5331100002 MUFFLER 1 2 0019112030 HEX. HEAD BOLT 4 2 0042312000 LOCK WASHER 4 2 0042412000 PLAIN WASHER 4 3 C5335200104 PACKING 2 4 C5335200204 PACKING 1 5 C5335200304 PACKING 1 6 0019110035 HEX. HEAD BOLT 24 6 0042310000 LOCK WASHER 24 6 0042410000 PLAIN WASHER 24 7 C5334000103 EXHAUST PIPE 2 7 C4334200504 GASKET 4 8 0010116070 HEX. HEAD BOLT 16 8 0030016000 HEX. NUT 16 8 0040016000 LOCK WASHER 16 8 0041216000 PLAIN WASHER 32 9 0010116050 HEX. HEAD BOLT 16 9 0040016000 LOCK WASHER 16 9 0041216000 PLAIN WASHER 16 10 7522355103 OUTLET PIPE 1 11 C5335200004 GASKET 1 12 0010116070 HEX. HEAD BOLT 4 12 0030016000 HEX. NUT 4 12 0040016000 LOCK WASHER 4 12 0041216000 PLAIN WASHER 8 13 7525125704 COVER 1 14 C5331300004 COVER 1 15 0017108020 HEX. HEAD BOLT 4

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 97

FUEL TANK ASSY.

DCA-800SSK — FUEL TANK ASSY.

PAGE 98 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C5364000303 FUEL TANK 1

2 0605505030 CAP, FUEL TANK ..................................... 1 .........REPLACES 0605505005

2A 0601850590 KEY, FUEL TANK CAP 1 3 0810105400 FUEL FILTER 1 4 0264100425 HOSE, FUEL GAUGE 1 5 0605515079 HOSE BAND 2 6 7435523104 TANK BAND 2 7 0805003414 PAD, TANK BAND 4 8 0017108020 HEX. HEAD BOLT 2 9 0207308000 HEX. NUT 2 10 0222100600 TANK SHEET 6 11 0130206000 STREET ELBOW, 1/2 3 12 7525512104 DRAIN PIPE 1 13 7525516504 BRACKET 1 14 0019108030 HEX. HEAD BOLT 2 15 0205008000 HEX. NUT 2 16 0042308000 LOCK WASHER 2 17 0042408000 PLAIN WASHER 2 18 0603325011 VALVE 1 19 0132006000 PLUG, 1/2 3 20 0605503009 FUEL SENSOR 1 21 0802120604 PACKING 1

22 0605501050 UNIT, FUEL .............................................. 1 .........52000-KA9810

23 0602021155 PACKING .................................................. 1 .........52391-KW3700

25 0022905015 MACHINE SCREW 5 25 0845039604 RUBBER SEAL 1 26 7435512104 LONG NIPPLE 2 27 0605511033 THREE WAY VALVE 2 28 0131506000 NIPPLE, 1/2 2 29 0130406000 T JOINT, 1/2 2 30 0602022293 HOSE JOINT 1 31 0602022203 HOSE JOINT 3 32 6185517204 HOSE JOINT 2 33 0191504300 SUCTION HOSE 1 34 0191302500 SUCTION HOSE 1 35 0191301100 SUCTION HOSE 1 36 0191004500 RETURN HOSE 1 37 0191002500 RETURN HOSE 1 38 0191001100 RETURN HOSE 1 39 0605515032 HOSE BAND 2 40 0605515014 HOSE BAND 6 41 0605515155 HOSE BAND 4 42 C5358300104 CLAMPER 1 43 0017110025 HEX. HEAD BOLT 2

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 99

ENCLOSURE #1 ASSY.

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:

THE SERIAL NUMBER MAY BE REQUIRED.

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

PAGE 100 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Multiquip DCA800SSK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual