Multiquip DCA800SSK2 User Manual
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA800SSK2
60HZ GENERATOR (STD.)
(KOMATSU SAA6D170E-3 DIESEL ENGINE)
PARTS LIST NO. C5871301004
Revision # (09/03/09)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffi c Safety Administration (NHTSA) in addition to notifying Multiquip at
18004211244.
If NHTSA receives similar complaints, it may open an investigation, and if it
fi nds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline tollfree at
18883274236 (TTY: 18004249153), go to http://www.nhtsa.dot.gov; or write
to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 3
TABLE OF CONTENTS
DCA800SSK2
60 Hz Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information ..............................................6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................ 14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ................................... 18-19
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-23
Load Application .................................................... 24
Generator Outputs ................................................. 25
Generator Outputs/Gauge Reading ....................... 26
Output Terminal Panel Connections ................. 27-28
Inspection/Setup ............................................... 29-32
Generator StartUp Procedure (Manual) .......... 34-35
Generator StartUp Procedure (Auto Mode) ........... 36
Generator ShutDown Procedures ......................... 37
Maintenance ..................................................... 38-41
Trailer Maintenance .......................................... 42-45
Trailer Wiring Diagram ........................................... 46
Generator Wiring Diagram ..................................... 47
Engine Wiring Diagram .......................................... 48
Controller Wiring Diagram ..................................... 49
Controller Wiring Diagram (Main Breaker) ............. 49
Troubleshooting (Generator) .................................. 50
Troubleshooting (MPEC) ....................................... 51
Troubleshooting (Engine Controller) ...................... 52
Explanation Of Code In Remarks Column............. 54
Suggested Spare Parts ......................................... 55
Component Drawings
Generator Assembly ......................................... 56-59
Control Panel Assembly ................................... 60-61
Control Box Assembly ...................................... 62-65
Engine Assembly ............................................. 66-69
Radiator Assembly ...........................................70-71
Alternator Assembly .........................................72-73
Thermostat Assembly ....................................... 74-75
Water Pump Assembly ..................................... 76-77
Starter Assembly .............................................. 78-79
Engine Operating Panel Assembly ................... 80-81
Output Terminal Assembly ................................ 82-85
Battery Assembly.............................................. 86-87
Muffl er Assembly .............................................. 88-89
Fuel Tank Assembly ......................................... 90-91
Enclosure Assembly #1 .................................... 92-95
Enclosure Assembly #2 .................................... 96-99
Enclosure Assembly #3 ................................ 100-103
Rubber Seals Assembly ............................... 104-105
Nameplate and Decals Assembly ................ 106-111
Terms and Conditions Of Sale — Parts ............... 112
PAGE 4 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 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.
When ordering parts, please supply:
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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
R Specify Preferred Method of Shipment:
UPS/Fed Ex DHL
N Priority One Tr uck
N Ground
N Next Day
N Second/Third Day
www.mqpower.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. 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.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fi re department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
PAGE 8 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order 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 mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
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. Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
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.
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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 11
Generator Specifi cationsTable 1.
Model DCA800SSK2 (Standard)
Type
Armature Connection Star with Neutral
Phase
Standby Output
Prime Output
Revolving fi eld, self ventilated,
open protected type synchronous generator
3
880 kVA (704 kW)
800 kVA (640 kW)
SPECIFICATIONS
Voltage - 1 Ø
Voltage - 3 Ø
Frequency
Speed
Power Factor
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Wet Weight
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
120, 127, 139, 240, 254, 277V Adjustable
208, 220, 240, 416, 440, 480V Reconnectable
60 Hz
1800 rpm
0.8
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
23,634 lbs. (10,720 kg.)
25,308 lbs. (11,479 kg.)
Engine Specifi cationsTable 2.
KOMATSU SAA6D170E3
4 cycle, watercooled, direct injection, turbocharged
airtoair intercooled
6 cylinders
6.69in. x 6.69 in. (170 mm x 170 mm)
1413 cu. in. (23,150 cc)
1008 HP/1800 RPM
Electric 24 VDC
40.4 gal. (153 liters)
37.2 gal. (141 liters)
#2 Diesel Fuel
129.5 gal. (490 liters)
41.3 gal. (156.5 L)/hr at full load 30.8 gal. (116.4 L)/hr at 75% load
22.6 gal. (85.9 L)/hr at 50% load 14.5 gal. (54.9 L)/hr at 25% load
12V 200Ah x 4 (24V System)
PAGE 12 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
DIMENSIONS
DimensionsFigure 1.
DimensionsTable 3.
Reference
Letter
A 43.31 in. (1,100 mm.) H 32.68 in. (830 mm.)
B 36.22 in. (920 mm.) I 39.37 in. (1000 mm.)
C 27.17 in. (690 mm.) J 29.53 in. (750 mm.)
D 43.31 in. (1,100 mm.) K 240.54 in. (6110 mm.)
E 29.53 in. (750 mm.) L 98.43 in. (2500 mm.)
F 39.37 in. (1000 mm.) M 76.77 in. (1950 mm.)
G 32.68 in. (830 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 13
INSTALLATION
Typical Generator Grounding ApplicationFigure 2.
PAGE 14 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
INSTALLATION
OUTDOOR INSTALLATION
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground (Figure 2).
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifi es that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 25064(b) and 25066 set the following
grounding requirements:
Use one of the following wire types to connect the 1.
generator to earth ground.
Copper 10 AWG (5.3 mm2) or larger.a.
Aluminum 8 AWG (8.4 mm2) or larger.b.
When grounding the generator (Figure 2) connect the 2.
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
INDOOR INSTALLATION
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 fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor or grade level (in
accordance to NFPA 110, Chapter 54.1). 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.
NEC article 25052(c) specifi es that the earth ground rod 3.
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 15
GENERAL INFORMATION
GENERATOR
The MQ Power Model DCA800SSK2 is a 640 kW generator
(Figure 3) that is 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 OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Emergency Stop Switch
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Pilot Lamp
PreHeat Lamp
Engine Speed Switch
Battery Switch
Engine Alarm Lamps (6)
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter ChangeOver Switch
Voltmeter ChangeOver Switch
Voltage Regulator
Panel Light/Panel Light Switch
3Pole, 2500 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Automatic Voltage Regulator•
Current Transformer•
OverCurrent Relay•
Voltage Rectifi er•
Starter Relay•
Engine Controller (Computer Controlled)•
Voltage ChangeOver Board•
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 240/139V output receptacles (CS6369), 50A
Three auxiliary circuit breakers, 50A
Eight output terminal lugs (3Ø power)
Battery Charger (Optional)
Water Heater (Optional)
OPEN DELTA EXCITATION SYSTEM
The DCA800SSK2 generator is equipped with the state
of the art “OpenDelta” excitation system. The open delta
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 rectifi ed 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 confi guration 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 opendelta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
The DCA800SSK2 is powered by a 6 cylinder, water
cooled, direct injection, turbocharged airtoair KOMATSU
SAA6D170E3 Diesel Engine. This engine is designed to
meet every performance requirement for the generator.
Reference Table 2 for engine specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
MAJOR COMPONENTS
Generator Major ComponentsTable 4.
ITEM NO. DESCRIPTION
1 Air Filter Assembly
2 Muffl er Assembly
3 Fuel Tank Assembly
4 Engine Operating Panel Assembly
5 Battery Assembly
6 Output Terminal Panel Assembly
7 Generator Assembly
8 Generator Control Panel Assembly
9 Engine Control Panel Assembly
Major ComponentsFigure 3.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 17
GENERATOR CONTROL PANEL
Generator Control PanelFigure 4.
The defi nitions below describe the controls and functions of
the DCA800SSK2 Generator Control Panel (Figure 4).
AC Voltmeter 1. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
Pilot Lamp 2. — Indicates the system is running.
Panel Light 3. — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
Frequency Meter 4. — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
AC Ammeter 5. — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phaseselector switch.
Voltmeter ChangeOver Switch 6. — 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.
Ammeter ChangeOver Switch 9. — This switch allows
the AC ammeter to indicate the current fl owing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
Circuit Breaker (ON) Switch10. — Press this switch to
place the 2500 amp circuit breaker in the closed (ON)
position.
Circuit Breaker (OFF) Switch11. — Press this switch to
place the 2500 amp circuit breaker in the open (OFF)
position.
CIircuit Breaker (ON) Lamp12. — When the circuit breaker
ON switch is placed in the ON position this lamp willl be
turned ON.
CIircuit Breaker (OFF) Lamp 13. — When the circuit
breaker ON switch is placed in the OFF position this
lamp will be turned ON.
Panel Light Switch 7. — When activated will turn on
control panel light.
Voltage Regulator Control 8. — Allows ±15% manual
adjustment of the generator’s output voltage.
PAGE 18 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR CONTROL PANEL
Auto On/Off Engine Controller (MPEC) 14. — This
controller has a vertical row of status LED’s (inset), that
when lit, indicate that an engine malfunction (fault) has
been detected. When a fault has been detected the
engine controller will evaluate the fault and all major
faults will shutdown the generator. During cranking
cycle, The MPEC will attempt to 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 shut down the engine 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 controller module.
Overcrank Shutdown — Indicates the unit has
attempted to start a pre programmed number of timesand
has failed to start. The number of cycles and duration are
programmable. It is preset at 3 cycles with a 10second
duration. This is considered a major fault.
Overspeed Shutdown — Indicates the engine is running
at an unsafe speed. This is considered a major fault.
Engine Running — Indicates that engine is running at
a safe operating speed.
Located behind the generator control panel is the
Generator Control Box. This box contains some of the
necessary electronic components required to make the
generator function.
The Control Box is equipped with the following major
components:
OverCurrent Relay
Voltage Rectifi er (AVR)
Starter Relay
Current Transformer
MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/RESET
position, the unit will not run. When this switch is set to the
manual position, the generator will start immediately.
If the generator is to be connected to a building’s AC
power source via a transfer switch (isolation), place the
switch in the AUTO position. In this position, should an
outage occur, the automatic transfer switch (ATS) will
start the generator automatically via the generator’s
autostart contacts connected to the ATS’s start contacts.
Please refer to your ATS installation manual for further
instructions for the correct installation of the autostart
contacts of the geerator to the ATS.
Low Oil Pressure — Indicates the engine pressure
has fallen below a safe operating level. The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
High Coolant Temperature — Indicates the engine
temperature has exceeded a safe operating level. The
engine temperature is detected using variable resistive
values from the temperature sending unit. This is
considered a major fault.
Voltage ChangeOver Board
Three Phase Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
fl owing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 2500 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 19
ENGINE OPERATING PANEL
L
Engine Operating PanelFigure 5.
The defi nitions below describe the controls and functions
of the DCA800SSK2 Engine Operating Panel (Figure 5).
Battery Switch 1. — This switch should be set to the ON
position during normal operation. When the engine has
been stop, place this switch in the OFF position. DO
NOT turn this switch during normal operation, it could
cause damage to the electrical equipment.
Engine Speed Switch 2. — This switch controls the
speed of the engine (low/high).
PreHeat Lamp 3. — When ECU is placed in AUX
position, preheat lamp will be ON. When preheat cycle
is completed, lamp will turn OFF.
PreHeat Button 4. — Push this button when the engine
is ready for starting during cold weather operating
conditions. Keep pushing until the preheat lamp is
off.
Emergency Stop Button 5. — Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a means of stopping the engine.
Tachometer 6. — Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
Oil Pressure Gauge 7. — During normal operation this
gauge be should read between 28 to 85 psi. (193~586
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
Water Temperature Gauge 8. — During normal
operation this gauge be should read between 167°
and 203°F (75°~95°C).
Charging Ammeter Gauge 9. — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
Fuel Gauge 10. — Indicates amount of diesel fuel available.
Engine Warning Lamps 11. — There are six engine
warning lamps, they are defi ned as follows:
Overheat Lamp a. — This lamp goes ON
when the cooling water temperature rises
abnormally. If the lamp goes ON during
normal operation of the generator, the
emergency shutdown device will stop the
engine automatically.
Low Oil Pressure Lamp b. — During
normal operation of the generator this
lamp should remain OFF. When the
AutoOFF/ResetManual switch is set to
the MANUAL position to start the engine,
the lamp will be lit. When the oil pressure
rises after startup the lamp will go OFF. If this lamp
is ever lit (ON) during normal operation of the
generator, the emergency shutdown device will stop
the engine automatically.
Low Fuel Level Lamp c. — When this lamp
is ON, it is time to stop the engine and
add fuel. Remember to let the engine cool
before adding fuel.
Air Filter Alarm d. — When the air fi lter
element is clogged, this lamp goes ON
indicating the element should be
immediately cleaned or replaced.
Oil Filter Alarm e. — This lamp goes ON
when the coolant level is low. If this lamp
goes ON while the engine is in operation,
the emergency shutdown device will
COOLANT LEVE
automatically stop the engine.
Water Level Lamp f. — This lamp goes ON
when the coolant level is low. If this lamp
goes ON while the engine is in operation,
the emergency shutdown device will
automatically stop the engine.
PAGE 20 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
NOTES
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is
located on the righthand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
Output Terminal PanelFigure 6.
PAGE 22 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
OUTPUT TERMINAL PANEL FAMILIARIZATION
Twist Lock Dual Voltage 240/139 VAC Receptacles
There are three 240/139V, 50 amp auxiliary twistlock
(CS6369) receptacles (Figure 7) provided on the output
terminal panel..
240/139V TwistLock Auxiliary Figure 7.
Receptacles
Each auxiliary receptacle is protected by a 50 amp
circuit breaker. These breakers are located directly above
the auxiliary receptacles. Remember the load output
(current) on all three receptacles is dependent on the load
requirements of the Output Terminal Lugs.
Connecting Loads
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 9).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3pole,
2500A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Connecting LoadsFigure 9.
Over Current Relay
Turn the voltage regulator control knob (Figure 8) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counterclockwise will decrease the voltage.
Voltage Regulator Control KnobFigure 8.
An over current relay (Figure 10) is connected to the main
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 reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
Over Current RelayFigure 10.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 23
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage 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 infl uenced by the effi ciency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Power Factor By LoadTable 5.
Type of Load Power Factor
Singlephase induction motors 0.40.75
THREE PHASE LOAD
When calculating the power requirements for 3phase power
use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motordriven equipment draw much greater
current for starting than during operation.
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 6.
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.
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.40.9
Electronic devices, communication
equipment
1.0
Common power tools 0.8
Cable Selection (60 Hz, Single Phase Operation)Table 6.
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
When connecting a fl uorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
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
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
PAGE 24 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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 changeover board
(Figure 11). To obtain some of the voltages as listed in
Table 7 (see below) will require a fi ne adjustment using
the voltage regulator (VR) control knob located on the
control panel.
Voltage ChangeOver Board
The voltage changeover board (Figure 11) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
Generator Amperage
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.
Generator Maximum AmpsTable 8.
Rated Voltage Maximum Amps
1Ø 120 Volt 1777.8 amps (4 wire)
1Ø 240 Volt 888.9 amps (4 wire)
3Ø 240 Volt 1924.6 amps
3Ø 480 Volt 962.3 amps
Voltage ChangeOver BoardFigure 11.
CAUTION
NEVER attempt to place jumper plates on the voltage
changeover board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
Voltages AvailableTable 7.
Three Phase
(Switchable)
Single Phase
(Switchable)
208V 220V 240V 416V 440V 480V
120V 1127V 139V 240V 254V 277V
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 25
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
The AC ammeter and AC voltmeter gauges are controlled by
the AC ammeter and AC voltmeter changeover switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, confi gure the
Voltage ChangeOver Board (Figure 12) which produces
the desired output voltage.
AC Ammeter Gauge Reading
Place the AC Ammeter ChangeOver Switch (Figure 16)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 16). This process can be repeated for
terminals V and W.
AC AmmeterFigure 15.
ChangeOver Switch
(Amp reading on U Lug
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
AC Ammeter Figure 16.
Voltage ChangeOver BoardFigure 12.
240/3
Ø Position
AC Voltmeter Gauge Reading
Place the AC Voltmeter ChangeOver Switch (Figure 13)
in the WU position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 14).
AC Voltmeter Figure 13.
ChangeOver Switch
AC Voltmeter GaugeFigure 14.
(Volt reading on WU Lug
PAGE 26 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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 ChangeOver Board (Figure 17) and the
adjustment of the Voltage Regulator Control Knob.
Remember the voltage changeover board determines the
range of the output voltage and can be confi gured 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 confi guration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
3Ø-240V UVWO Terminal Output Voltages
Jumper the voltage changeover board for 240V 1.
operation as shown in Figure 17.
Turn the voltage regulator knob (Figure 19) clockwise 3.
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required
Voltage Regulator KnobFigure 19.
1Ø-240V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 240V operation as shown in Figure 17.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 20.
Voltage ChangeOver Board 240V Figure 17.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 18.
UVWO Terminal Lugs 1Ø240V Figure 20.
Connections
1Ø-120V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 240V operation as shown in Figure 17.
Adjust voltage regulator knob (Figure 19) for an output 2.
of 208V to obtain 120V at the UVWO terminals.
Connect the load wires to the UVWO terminals as 3.
shown in Figure 21.
UVWO Terminal LugsFigure 18.
UVWO Terminal Lugs Figure 21. 1Ø139V
Connections
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 27
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
Jumper the voltage changeover board for 480V 1.
operation as shown in Figure 22. This confi guration
uses 6 jumper plates in 3 different positions. Remember
there are 2 jumper plates at every position. Every
jumper plate must be used.
Voltage ChangeOver Board 480V Figure 22.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 23.
1Ø-480V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 480V operation as shown in Figure 22.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 24.
UVWO Terminal Lugs 1Ø480V Figure 24.
Connections
1Ø-277V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 480V operation as shown in Figure 22.
UVWO Terminal Lugs 3Ø480V Figure 23.
Connections
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fi re.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 25.
UVWO Terminal Lugs 1Ø277V Figure 25.
Connections
PAGE 28 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
INSPECTION/SETUP
CIRCUIT BREAKERS
To protect the generator from an overload, a 3pole, 2500
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition, three
50 amp load circuit breakers have been provided to protect
the auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
LUBRICATION OIL
Fill the engine crankcase with lubricating oil through the
fi ller hole, but DO NOT overfi ll. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 26) on the dipstick. See Table 11 for
proper selection of engine oil.
Engine Oil DipstickFigure 26.
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 refi ll with the specifi ed 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:
FUEL CHECK
DANGER
Fuel spillage on a hot engine can cause
a fi re or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refi lling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understand this section should refi ll the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 27). ALWAYS fi ll the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fi ll 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 fi lling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
API Service Classifi cation CC/SC
API Service Classifi cation CC/SD
API Service Classifi cation CC/SE
API Service Classifi cation CC/SF
Recommended Motor OilTable 9.
Internal Fuel Tank SystemFigure 27.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 29
INSPECTION/SETUP
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
Level Tanks1. — 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 (Figure 28).
CAUTION
ALWAYS place trailer on fi rm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Open cabinet doors on the “right side” of the generator 2.
(from generator control panel position). Remove fuel
cap and fi ll tank (Figure 29).
Fueling the GeneratorFigure 29.
NEVER overfi ll fuel tank3. — It is important to read the
fuel gauge when fi lling trailer fuel tank. DO NOT wait
for fuel to rise in fi ller neck (Figure 30).
Only Fill on Level GroundFigure 28.
NOTICE
ONLY use #2 diesel fuel when refueling.
Full Fuel TankFigure 30.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 31).
Fuel ExpansionFigure 31.
PAGE 30 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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