Multiquip DCA800SSK2 - Manuals

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 5 PARTS ORDERING PROCEDURES www .mqpo w e r .com Ordering parts has never been easier! Choose from three easy options: WE ACCEPT ALL MAJOR CREDIT CARDS! When ordering parts, please supply: R Dealer Account Number R D...

PAGE 6 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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 safe...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 7 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 d...

PAGE 8 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 9 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 w...

PAGE 10 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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. T h e e l e c t r i c...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 11 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 ...

PAGE 12 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) SPECIFICATIONS Generator Specifi cations Table 1. Model DCA800SSK2 (Standard) Type Revolving fi eld, self ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase 3 Standby...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 13 DIMENSIONS Dimensions Figure 1. Dimensions Table 3. Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) 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....

PAGE 14 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) INSTALLATION Typical Generator Grounding Application Figure 2.

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 15 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 a...

PAGE 16 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) GENERATOR The MQ Power Model DCA800SSK2 is a 640 kW generator (Figure 3) that is designed as a high quality por table (requires a trailer for transport) power source for telecom sites, lighting facilities, power t...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 17 MAJOR COMPONENTS Major Components Figure 3. Generator Major Components Table 4. ITEM NO. DESCRIPTION 1 Air Filter Assembly 2 Muffl er Assembly 3 Fuel Tank Assembly 4 Engine Operating Panel Assembly 5 Battery Assem...

PAGE 18 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) GENERATOR CONTROL PANEL Generator Control Panel Figure 4. The defi nitions below describe the controls and functions of the DCA800SSK2 Generator Control Panel (Figure 4). AC Voltmeter 1. — Indicates the output vol...

PAGE 20 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) ENGINE OPERATING PANEL 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...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 21 NOTES

PAGE 22 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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 gai...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 23 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. . 2...

PAGE 24 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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 gener...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 25 GENERATOR OUTPUTS Generator Amperage Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed. Generator Maximum Amps Table 8. Rated Voltage Maximum Amps 1Ø 120 Volt 1777....

PAGE 26 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) GENERATOR OUTPUTS/GAUGE READING H OW TO R E A D T H E AC A M M E T E R A N D AC VOLTAGE GAUGES The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter changeover switches. Both of ...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 27 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 jump...

PAGE 28 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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 posi...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 29 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 ...

PAGE 30 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) INSPECTION/SETUP Refueling Procedure: Level Tanks 1. — 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). Only Fill o...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 31 COOLANT (ANTIFREEZE/SUMMER COOLANT/WATER) Komatsu recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or prediluted. See th...

PAGE 32 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) BATTERY This unit is of negative ground DO NOT connect in reverse. Always maintain battery fl uid level between the specifi ed marks. Battery life will be shortened, if the fl uid level are not properly maintained...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 33 GENERATOR STARTUP PROCEDURE (MANUAL) BEFORE STARTING If applicable perform the following: Apply commercial power to the internal battery charger  receptacle (to ensure good starting) via commercial power. An exte...

PAGE 34 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) GENERATOR STARTUP PROCEDURE (MANUAL) STARTING (MANUAL) Set the 1. battery ON/OFF switch (Figure 39) to the " ON " position. Battery Switch (ON) Figure 39. Place the 2. engine speed switch in the " LOW ...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 35 GENERATOR STARTUP PROCEDURE (MANUAL) Press the 14. main circuit breaker " ON" switch (Figure 52). Main Circuit Breaker ON Switch Figure 52. Verify that the main circuit breaker " 15. ON " lamp (Fig...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 37 GENERATOR SHUTDOWN PROCEDURES NORMAL SHUTDOWN PROCEDURE To shutdown the generator, use the following procedure: Place the three 1. auxiliary circuit breakers in the OFF position (Figure 36) Place the engine speed ...

PAGE 38 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) * 1 Replace engine oil and fi lter at 100 hours, fi rst time only. * 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant. * 3 Replace primary air fi lter element when restriction indicato...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 39 MAINTENANCE If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel c...

PAGE 40 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) CHECK OIL LEVEL Check the crankcase oil level prior to each use, or when the fuel tank is fi lled. Insuffi cient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be b...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 41 MAINTENANCE JACKET WATER HEATER AND INTERNAL BATTERY C H A R G E R 1 2 0 VAC I N P U T R E C E P TAC L E S (OPTIONAL) This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on...

PAGE 42 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) TRAILER MAINTENANCE TRAILER MAINTENANCE This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refe...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 43 TRAILER MAINTENANCE ELECTRIC BRAKES Electr ically actuated brakes (Figure 66) are similar tohydraulic brakes. the basic difference is that hydraulic brakes are actuated by an electromagnet. listed below are some o...

PAGE 44 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) TRAILER MAINTENANCE TIRES/WHEELS/LUG NUTS Tires and wheels are a ver y impor tant and cr itical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axl...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 45 TRAILER MAINTENANCE 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...

PAGE 46 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) TRAILER WIRING DIAGRAM Trailer/Towing Vehicle Wiring Diagram Figure 69.

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 47 GENERATOR WIRING DIAGRAM Generator Wiring Diagram Figure 70.

PAGE 48 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) GENERATOR WIRING DIAGRAM (MAIN BREAKER) Engine Wiring Diagram Figure 71.

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 49 ENGINE WIRING DIAGRAM Controller Wiring Diagram Figure 72.

PAGE 52 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) TROUBLESHOOTING (ENGINE CONTROLLER) This generator is equipped with an electronic governor for unit injection system. The engine controller (Figure 73), consists of a display, switches, trimmer, etc., for monitori...

PAGE 54 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) 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 a...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 55 SUGGESTED SPARE PARTS DCA800SSK2 WHISPERWATT GENERATOR WITH KOMATSU SAA6D170E3 DIESEL ENGINE 1 to 3 units QTY. P/N DESCRIPTION 12..........0602046653 .......... AIR FILTER, ELEMENT, OUTER6............0602046653-1 ...

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 73 ALTERNATOR ASSY. (S/N 311209 AND ABOVE) NO. PART NO. PART NAME QTY. REMARKS 1 6240816150 PULLEY, NON HARDENING 1 2 6240816180 BELT, ALTERNATOR 1 3 6008253161 ALTERNATOR, ASSY 1

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 79 STARTER ASSY. (S/N 316346 AND ABOVE) NO. PART NO. PART NAME QTY. REMARKS 1 6008133512 STARTING MOTOR ASSY. (7.5 KW) 2 2 6221816810 GASKET 2 3 0101061645 BOLT 6 4 0164331645 WASHER 6

PAGE 80 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) ENGINE OPERATING PANEL ASSY.

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 81 ENGINE OPERATING PANEL ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 C5484001202 SUPPORT LEG 1 2 0017112045 HEX HEAD BOLT 4 2A 0030012000 HEX NUT 4 2B 0041212000 WASHER, FLAT 4 3 0019210025 HEX HEAD BOLT 2 3A 020501...

PAGE 82 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) OUTPUT TERMINAL ASSY.

PAGE 106 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) NAMEPLATE AND DECALS ASSY.

DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 111 NAMEPLATE AND DECALS ASSY. (CONTINUED) NO. PART NO. PART NAME QTY. REMARKS 11 C1552000403 DECAL : HANDLING PROCEDURES .................................1 ........... C15200040 CONTROL PANEL & BOX GROUP 21 0800...

PAGE 112 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) TERMS AND CONDITIONS OF SALE — PARTS PAYMENT TERMS Terms of payment for parts are net 30 days. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipmen...

OPERATION AND PARTS MANUAL Your Local Dealer is: HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2009, MULTIQUIP INC. MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written...