Multiquip Portabel Generator Standard Dca 800Ssk Users Manual DCA800SSK Rev 4 060310

MQ Power WhisperWatt 800 Generator DCA800SSK Generators_portable_whisperwatt_DCA800SSK_rev_4_std_manual_DataId_19118_Version_1

DCA-800SSK to the manual ab06fc7c-0b5d-44ed-9c9e-a183bb953639

2015-02-09

: Multiquip Multiquip-Portabel-Generator-Standard-Dca-800Ssk-Users-Manual-558573 multiquip-portabel-generator-standard-dca-800ssk-users-manual-558573 multiquip pdf

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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

MODEL DCA-800SSK

PORTABLE GENERATOR

(STANDARD)

Revision #4 (06/03/10)

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

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

Diesel engine exhaust and some of

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

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

DCA-800SSK TABLE OF CONTENTS

MQ Power DCA-600SSKMQ Power DCA-600SSK

MQ Power DCA-600SSK

AC GeneratorAC Generator

AC 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 DRAWINGSWINGS

WINGSWINGS

WINGS

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

Specification and part

number are subject to

change without notice.

NOTE

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

PARTS ORDERING PROCEDURES

www.mqpower.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 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

R Specify Preferred Method of Shipment:

UPS/Fed Ex DHL

N Priority One Tr u c k 

N Ground

N Next Day

N Second/Third Day

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 you

District Sales Manager for more information.

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

Note: Discounts Are Subject To Change

Goto www.multiquip.com and click on

Order Parts to log in and save!

Use the internet and qualify for a 5% Discount

on Standard orders for all orders which include

complete part numbers.*

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)

Fax your order in and qualify for a 2% Discount

on Standard orders for all orders which include

complete part numbers.*

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

Best Deal!

International Customers should contact

their local Multiquip Representatives for

Parts Ordering information.

Non-Dealer Customers:

Contact your local Multiquip Dealer for

parts or call 800-427-1244 for help in

locating a dealer near you.

Note: Discounts Are Subject To Change

Effective:

January 1st, 2006

NOTICE

All orders are treated as Standard Orders and will

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

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

DCA-800SSK — SPECIFICATIONS

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

NOTE PAGE

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

DCA-800SSK — DIMENSIONS (TOP AND SIDE)

Figure 1. Dimensions

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

Figure 2. Dimensions

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

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

DCA-800SSK — SAFETY MESSAGE ALERT SYMBOLS

Before using this generator, ensure that the operating

individual has read and understands all instructions in

this manual.

Safety precautions should be followed at all times when

operating this equipment. Failure to read and understand the

Safety Messages and Operating Instructions could result in

injury to yourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS

Potential hazards associated with the operation of this

equipment will be referenced with "

Hazard Symbols

" which

appear throughout this manual, and will be referenced in

conjunction with Safety "

Message Alert Symbols

NOTE

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.

You COULD be KILLED or SERIOUSLY injured if

you do not follow directions.

You CAN be injured if you do not follow directions

Gasoline engine exhaust gases contain

poisonous carbon monoxide. This gas is

colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

equipment in a confined area or enclosed structure that

does not provide ample free flow air.

Gasoline

is extremely flammable, and

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.

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.

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.

WARNING

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, there

exists the possibility of

electrocution,

electrical shock or burn,

which can cause

severe bodily harm

or even

DEATH!

DANGER - ELECTROCUTION HAZARDS

You WILL be KILLED or SERIOUSLY injured if you

do not follow directions.

DANGER

This

Operation and Parts

Manual

has been developed to provide

complete instructions for the safe

and efficient operation of the MQ

Power

Model DCA-800SSK (60Hz)

Whisperwatt™ Generator.

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

DCA-800SSK — SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the engine ON/OFF

switch in the OFF position when the

generator is not in use.

ALWAYS wear approved

respiratory

protection.

ALWAYS wear approved

eye

and

hearing

protection.

Other important messages are provided throughout this

manual to help prevent damage to your generator, other

property, or the surrounding environment.

This generator, other property,

or the surrounding environment

could be damaged if you do not

follow instructions.

NOTE

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.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,

or guards removed. Keep

fingers

hands

hair

and clothing away from all moving

parts to prevent injury.

WARNING - ROTATING PARTS

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

DCA-800SSK — RULES FOR SAFE OPERATION

The following safety guidelines should always be used when

operating the DCA-800SSK

(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

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.

Failure to follow instructions in this manual may lead to

serious injury

or even

DEATH

! This equipment is to be

operated by trained and qualified personnel only! This

equipment is for industrial use only.

DANGER - READ THIS MANUAL!

■

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

bodily harm or even death.

■

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.

NEVER

operate the generator in any

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.

■

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

manual mode

unattended.

■

Refer to the

Komatsu Engine Owner's Manual

for

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.

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

DCA-800SSK — RULES FOR SAFE OPERATION

POWER

CORD

(POWER ON)

WET

HANDS

During operation of this generator, there

exists the possibility of

electrocution,

electrical shock or burn,

which can cause

severe bodily harm

or even

DEATH!

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

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.

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

DANGER - ELECTROCUTION HAZARDS

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 practical.

The following safety recommendations should also be

followed:

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

per the

National Electrical Code

(NEC) and

local codes before operating generator. Severe

injury

DEATH!

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.

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

lay in wate

■

NEVER

stand in water

while AC power from the generator

is being transfer to a load.

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

DCA-800SSK — RULES FOR SAFE OPERATION

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,

always

wear

safety glasses.

■

Use well insulated gloves when picking up the battery.

Maintenance Safety

■

The electrical voltage required to operate the generator

can cause severe injury or even death through physical

contact with live circuits.

Turn all circuit breakers OFF

before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a

running machine.

■

ALWAYS disconnect the

NEGATIVE battery terminal

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.

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.

■

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.

WARNING - BURN HAZARDS

■■

■

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

clothing or skin

, rinse skin or clothing

immediately with plenty of water.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

contact with your

EYES

, rinse eyes immediately with

plenty of water and contact the nearest doctor or hospital

to seek medical attention.

The risk of an explosion exists when performing service

on the battery. To avoid

severe injury

DEATH:

■■

■

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.

DANGER - EXPLOSION HAZARDS

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

Emergencies

■

ALWAYS know the location of the

nearest

fire extinguisher

■

ALWAYS know the location of the

nearest and

first aid kit

■

ALWAYS know the location of the

nearest phone or

keep a phone on

the job site,

in case of emergencies.

■

ALWAYS have easy access to the phone

numbers of the nearest

Ambulance

Doctor

and

Fire Department

. This information will

be invaluable in the case of an emergency.

DCA-800SSK — RULES FOR SAFE OPERATION

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.

CAUTION - FOLLOW TOWING REGULATIONS

■

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

chock blocks

underneath wheel to prevent rolling,

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

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

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:

■

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

Towing & Transporting Safety

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.

Trailer tires should be inflated 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 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.

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

Figure 3. Typical Generator Grounding Application

DCA-600SSK — INSTALLATION

DCA-800SSK — INSTALLATION

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

Outdoor Installation

Install the generator in a area that is free of

debris

bystanders

, and

overhead obstructions

. Make sure the

generator is on secure level ground so that it cannot slide or

shift around. Also install the generator in a manner so that

the 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.

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 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.

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

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.

a. Copper - 10 AWG (5.3 mm2) or larger.

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

2. When grounding the generator (Figure 3) connect the

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.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried aminimum of 8 ft. into the ground.

When connecting the generator to

any buildings electrical system

ALWAYS consult with a licensed

electrician.

DCA-800SSK — INSTALLATION

NOTE

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.

CAUTION - EXHAUST HAZARD

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

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:

Towing Safety Precautions

■

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

■

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

chocked 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 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.

■

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".

DCA-800SSK — TOWING RULES FOR SAFE OPERATION

Figure 4. Generator and Trailer

Check with your county or state safety towing regulations

before towing your generator.

CAUTION - TOWING REGULATIONS

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

Explanation of Chart:

This section is intended to provide the user with trailer ser-

vice and maintenance information. The service and mainte-

nance 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 dam-

age to the equipment and personal injury.

It is the purpose of this section to cover the major mainte-

nance components of the trailer. The following trailer com-

ponents 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 trans-

porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

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

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

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

the rear bumper (reflector).

DCA-800SSK — TRAILER-SAFETY GUIDELINES

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 sup-

port 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.

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.

CAUTION - TRAILER INSPECTION

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 — TRAILER-SPECIFICATIONS

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

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.

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 — OPERATION AND SAFETY DECALS

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

DCA-800SSK — GENERAL INFORMATION

DCA-600SSK FAMILIARIZATION

Generator

The MQ Power Model DCA-800SSK is a 640 kW

generator

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

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.

Open Delta Excitation System

The DCA-800SSK generator is equipped with the state of

the art "

Open-Delta

" 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 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 "

fixed ceiling

" and responds

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

engine.

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.

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

DCA-600SSK — MAJOR COMPONENTS

DCA-800SSK — MAJOR COMPONENTS

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

Figure 6. Generator Control Panel

DCA-800SSK — GENERATOR CONTROL PANEL

Up to S/N 3699247

S/N 3699248~

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

DCA-800SSK — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the

DCA-800SSK "

Control Panels

" (Figure 9).

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.

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

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

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 the generator will monitor

the AC line output from the building's power source.

B. Low Oil Pressure – Indicates the engine pressure has

fallen below 15 psi. The oil pressure is detected using

variable resistive values from the oil pressure sending unit.

This is considered a

major

fault.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 215

F. The engine temperature

is detected using variable resistive values from the

temperature sending unit. This is considered a

major

fault.

D. Overcrank Shutdown – Indicates the unit has attempted

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

fault.

E. Overspeed Shutdown – Indicates that the engine is

running at an unsafe speed. This is considered a

major

fault.

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

safe operating speed.

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

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

During

cranking cycle

, The engine controller 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 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.

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

DCA-800SSK — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panels

Up to S/N 3699247

S/N 3699248~

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

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 "

green

" zone.

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 (S/N 3699248~) – This switch

changes the engine speed from

low

(idle) to

high

14. Preheat Button – Press and hold this button for

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

E. Clogged Air Filter Lamp - This indicates

the air filter is clogged. Stop the engine

and replace the air filter.

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.

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,

pre-heat

stop

run

and

start

. Insert ignition

key to start and stop engine..

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:

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.

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

engine.

DCA-800SSK — ENGINE OPERATING PANEL

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

DCA-800SSK — OUTPUT TERMINAL OVERVIEW

Figure 8. Output Terminal Panel

Output Terminal Familiarization

The “

Output Terminal Panel

” (Figure 8) is provided with

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

Output Terminal Panel

Shown below (Figure 8) is the

Output Terminal Panel

, lift

up on the cover to gain access to receptacles and terminal

lugs.

Terminal legs "O" and "Ground"

are considered

bonded grounds

NOTE

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

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

voltage change-over

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

reset

button resets the GFCI receptacle after

being tripped. Pressing the "

Test Button

" (See Figure 9) in

the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

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

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

voltage regulator control knob

(Figure 11) on the

control panel to obtain the desired voltage. Turning the knob

clockwise will

increase

the voltage, turning the knob counter-

clockwise will

decrease

the voltage.

Figure 10. 240/139 VAC Twist-Lock

Auxiliary Receptacles

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.

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.

After the load wires have been securely attached to the

UVWO terminals, reinstall the plastic face plate. Place the

terminal cover in the down position and secure the locking

latch.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (UVWO Terminals)

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

DCA-800SSK — OUTPUT TERMINAL PANEL OVERVIEW

Figure 13. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the UVWO terminal

lugs or the convenience receptacles. (See Figure 13). Make

sure to read the operation manual before attempting to connect

a load to the generator.

To protect the UVWO output terminals from overload, a 3-

pole, 1,600 amp,

main

circuit breaker is provided. Make

sure to switch

ALL

circuit breakers to the "OFF" position

prior to starting the engine.

Over Current Relay

over current relay

(Figure 14) 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 cur-

rent relay must be pressed. The over current relay is lo-

cated in the control box.

Figure 14. Over Current Relay

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.

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

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

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

starting system of the equipment.

Motors and motor-driven equipment

draw much greater current for

starting than during operation.

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

If wattage is not given on the equipment's

name plate, approximate wattage may be

determined by multiplying nameplate

voltage by the nameplate amperage.

If 3Ø load (kVA) is not given on

the equipment nameplate,

approximate 3Ø load output

maybe determined by multiplying

voltage by amperage by 1.732.

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)

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.

NOTE

WATTS = VOLTAGE x AMPERAGE

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

when connecting loads.

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation:

NOTE

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.

NOTE

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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.

DANGER - ELECTRICAL SYSTEM HAZARDS

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

Generator Output Voltages

A wide range of voltages are available to supply voltage for

many different applications. Voltages are selected by apply-

ing jumpers (6) to the

voltage change-over board

(Figure 15).

To obtain some of the voltages as listed in Table 7 (see

below) will require a fine adjustment using the

voltage regu-

lator

(VR)

control knob

located on the control panel.

Voltage Change-Over Board

The

voltage change-over board

(Figure 15) is located on

the control box, behind the generator control panel. This

board has been provided for ease of voltage selection.

Figure 15. Voltage Change-Over Board

240V Configuration

DCA-800SSK — GENERATOR OUTPUTS

Generator Amperage

Tables 8 and 9 describe the generator’s current output capa-

bility for both 1Ø-phase and 3Ø phase applications.

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004770,2302,1240,11

064883,2383,1991,1296

025007,2465,1553,1287

085110,3447,1115,1278

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NEVER attempt to place jumper plates on the

voltage

change-over board

while the generator is in operation.

There exists the possibility of

electrocution, electrical

shock or burn, which can cause severe bodily harm

or even death!

CAUTION - CHANGING JUMPER PLATES

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

DCA-800SSK — GENERATOR OUTPUTS/GAUGE READING

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

AC Voltmeter

Change-Over

Switch

(Figure 17) to the W-U position and

the

AC Ammeter Change-Over Switch

(Figure 19) to the U

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

The

ammeter

and

voltmeter

gauges are only active when the

UVWO terminals are in use.

NOTE

Figure 16. Voltage Change-Over Board

240V Configuration

Maximum Amps

Table 10 shows the

maximum

amps the generator can pro-

vide. DO NOT exceed the maximum amps as listed.

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 17. AC Voltmeter

Change-Over Switch

40 60

Figure 20. AC Ammeter

(Amp reading on U lug)

Figure 19. AC Ammeter

Change-Over Switch

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

Figure 21. Voltage Change-Over Board

240V Configuration

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 de-

pendent on the placement of the jumpers plates (6) on the

Voltage Change-Over Board

and the adjustment of the

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.

Figure 22. UVWO Terminal Lugs

3Ø-240V Connections

2. Connect the load wires to the UVWO terminals as shown

in Figure 22.

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 23. Voltage Regulator Knob

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 24. UVWO Terminal Lugs

1Ø-240V Connections

Figure 25. UVWO Terminal Lugs

1Ø-139V Connections

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.

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

2. Connect the load wires to the UVWO terminals as shown

in Figure 27.

DCA-800SSK — OUTPUT TERMINAL 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

be used.

Figure 26. Voltage Change-Over Board

480V Configuration

Figure 27. UVWO Terminal Lugs

3Ø-480V Connections

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.

1Ø-277V 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 29.

Figure 29. UVWO Terminal Lugs

1Ø-277V Connections

ALWAYS make sure that the

connections to the UVWO

terminals are

secure

and tight.

The possibility of arcing exists,

that could cause a fire.

NOTE

Figure 28. UVWO Terminal Lugs

1Ø-480V Connections

NEVER attempt to connect a load to the UVWO output

terminals while the generato

is operating. The possibility

exists of serious injury, electrical shock, electrocution even

death.

DANGER - UVWO OUTPUT TERMINALS

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

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.

DCA-800SSK — PRE-SETUP

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.

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

from overload. Make sure to switch

ALL

circuit breakers to

the "OFF" position prior to starting the engine.

API Service Classification CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

Other types of motor oils may be substituted if they meet

the following requirements:

Figure 31 Double Fuel Tank System

REFILLING THE FUEL SYSTEM

The DCA600SSK series generators may (if equipped with a

trailer or skid) have a

double fuel tank system

(Figure 31),

which consists of an

internal

generator fuel tank, and a

trailer mounted

fuel tank. It is also possible the generator

can be equipped with a

skid mounted

fuel tank (Figure 32).

The skid type fuel system does not use the internal generator

fuel tank.

Use the instructions in this section that applies to your type

of fuel tank system.

ALWAYS

fill the fuel tank with clean and fresh

#2 diesel

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.

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Fuel Check

Fuel spillage on a

hot

engine can cause a

fire

explosion

If fuel spillage occurs, wipe up the spilled fuel completely

to prevent fire hazards. NEVER smoke around or near the

generator.

DANGER - EXPLOSION/FIRE HAZARDS

ONLY properly trained personnel who have read and

understand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

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

DCA-800SSK — PRE-SETUP

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.

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

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

Figure 33. Only Fill on Level Ground

ONLY! use

#2 diesel fuel

when

refueling.

NOTE

Fuel from the secondary inner

tank will eventually drain into the

primary trailer tank.

Figure 32. Skid Type Fuel Tank System

ALWAYS

place trailer on firm level ground before refueling

to prevent spilling and maximize the amount of fuel that

can be pumped into the tank.

CAUTION - REFUELING THE GENERATOR

Refilling Procedures

Diesel fuel and its vapors are dangerous

to your health and the surrounding

environment. Avoid skin contact and/or

inhaling fumes.

WARNING - RESPIRATORY HAZARDS

ALWAYS!

fill trailer tank

first

with

#2 diesel

fuel

, before

filling secondary internal tank.

CAUTION - TRAILER FUEL TANK

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

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

Figure 36. Filling Secondary Internal Fuel Tank

Figure 38. Fuel Expansion

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.

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.

Figure 37. Full Fuel System

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

CAUTION - REFUELING THE GENERATOR

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.

CAUTION - REFUELING SECONDARY FUEL TANK

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

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

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.

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

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.

Operation Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 13) has been added.

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

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

negative

battery terminal disconnected.

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

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.

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.

Figure 39. Fan Belt Tension

DCA-800SSK— PRE-SETUP

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

less than 50%.

NOTE

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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.

WARNING - BURN HAZARDS

NEVER place hands near the belts or fan while the

generator set is running.

CAUTION - ROTATING PARTS

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

DCA-800SSK— PRE-SETUP

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the

ignition

switch is in either the Pre-

Heat, 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.

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 (

fuel

oil

) lines are defective replace them

immediately

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.

NOTE

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.

Always

keep the terminals firmly tightened.

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

disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting

of the generator, and create other malfunctions.

CAUTION - BATTERY SERVICING SAFETY

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

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

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

Figure 43. Load Connections

Generator and Control Panel

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

Figure 44. Engine Enclosure Doors

Steps 1 thru 19 are referenced

for Engine Operating Panel up

to S/N 3699247. See Figure 41

below. This panel has an

igni-

tion

switch

NOTE

Figure 41. Engine Operating Panel

Up To S/N 3699247

1. Place the

main, G.F.C.I.

and

aux.

circuit

breakers (Figure 42)

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

2. Connect the load to the

UVWO

terminals or

auxiliary

receptacles

as shown in Figure 43. These load

connection points can be found on the output terminal

panel. To gain access to the UVWO terminals or other

power receptacles, unlock the access cover and lift the

door.

3. The UVWO terminals are protected by a plastic cover,

remove this cover to gain access to the terminals.

Tighten terminal nuts securely to prevent load wires from

slipping out.

Figure 42. Main, Aux. and GFCI

Circuit Breakers (OFF)

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

Before Starting

NEVER!

manually start the engine with the

main

GFCI

auxiliary

circuit breakers in the ON (closed) position.

CAUTION - LETHAL EXHAUST HAZARD

WARNING - STARTING THE GENERATOR

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

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

Figure 52. Voltage Adjust Control Knob

Figure 53. Ammeter (No Load)

13. The ammeter (Figure 53) will indicate zero amps with no

load applied. When a load is applied, the ammeter will

indicate the amount of current that the load is drawing

from the generator.

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

8. Place the

engine throttle lever

in the “LOW” position

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

panel.

Figure 50. Frequency Meter (Hz)

Figure 49. Engine Ignition Switch

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 48. Engine Throttle Control

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.

6. When starting the generator in COLD weather conditions,

turn the

ignition key

to the “PREHEAT

” position (Figure 46),

Figure 46. Ignition Switch (Pre-Heat)

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

displaying the 60 cycle output frequency in HERTZ.

5. Set the

battery ON/OFF switch

(Figure 45) to the “ON”

position.

Figure 45. Battery ON/OFF Switch

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

14. The engine oil pressure gauge (Figure 47) will indicate

the oil pressure (kg/ cm2) of the engine. Under normal

operating conditions the oil pressure is approximately

Figure 47. Oil Pressure Gauge

Figure 49. Engine Tachometer 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.

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

Figure 48. Coolant Temperature Gauge

WATER TEMP

048

kg/cm2

ENGINE OIL PRESSURE

Figure 50. Main, Aux. and GFCI

Circuit Breakers (ON)

17. Place the

main

GFCI

, and

aux

. circuit breakers in the

“ON” position (Figure 50).

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

reading if a load is in use.

19. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 51. Ammeter (Load)

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

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

Steps 20 thru 26 are referenced

for Engine Operating Panel

S/N 3699248~. See Figure 59

below. This panel does not have

an ignition switch. It does have

“

pre-heat button

” and a “

en-

gine speed switch

” that is

used in conjunction with the

MPEC unit.

NOTE

Figure 59. Engine Operating Panel

S/N 3699248~

20. Set the

battery ON/OFF switch

(Figure 60) to the “ON”

position.

Figure 60. Battery ON/OFF Switch

Figure 60. Pre-Heat Button/ Lamp

21. Press and hold the engine preheat button (Figure 59)

until the preheat lamp is lit (ON).

22. Place the engine speed switch in the “

LOW

” position

(Figure 62).

Figure 63. Auto-Off/Reset-Manual Switch

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 62. Engine Speed Switch (High)

24. Once the engine is warm and the engine is running

properly, place the engine speed switch in the “

HIGH

”

position (Figure 64).

Figure 64. Engine Speed Switch (High)

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

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

Figure 65. Engine Running LED (ON)

BEFORE STARTING

Generator and Control Panel

26. Continue operating the generator as outlined in steps

11 thru 19 (pages 46-47).

Pre-Heat

Lamp

Pre-Heat

Button

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

NEVER!

manually start the engine with the

main

GFCI

auxiliary

circuit breakers in the ON (closed) position.

WARNING - STARTING THE GENERATOR

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

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

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

Before Starting

section

(page 45) as outlined in the

Manual Starting

Procedure

Figure 67. Engine Speed Switch (High)

Figure 68. Off/Manual Auto Switch (AUTO)

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

MPEC unit to the AUTO position.

NOTE

When the generator is set in the “

AUTO ” mode, the generator will

automatically start

in the event of

commercial power falling below a

prescribed level by means of a

contact closure that is generated

automatically by a transfer switch.

2. Set the

battery ON/OFF switch

(Figure 66) to the “ON”

position.

Figure 66. Battery ON/OFF Switch

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

position.

5. Continue operating the generator as outlined in steps

11 thru 19 (pages 46-47).

Starting (Auto Mode)

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.

DANGER - ELECTRICAL SYSTEM HAZARDS

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.

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.

WARNING - AUTO MODE MAINTENANCE

CAUTION - BACKUP GENERATOR USE

The

Engine Speed Switch

must be set to the “High”

position when running in the

Auto-Start

mode. Failing to

set the switch in the proper position can result in damage

to your generator when it turns on.

CAUTION - ENGINE SPEED SWITCH

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

Figure 71. Ignition Key Switch (STOP position)

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

(Figure 69) to the "OFF position".

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

load applied.

5. Remove all loads from the generator.

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

Figure 70. Engine Throttle Control

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

Figure 69. Main, Aux. and GFCI

Circuit Breakers (OFF)

Engine Shutdown Controller (S/N 3698617~)

To shutdown the generator use the following procedure:

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

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

2. Place the engine speed switch in the “

LOW

” position

(Figure 73).

Figure 73. Engine Speed Switch (High)

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

load applied.

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

the

OFF/Reset

position.

Figure 74. Off/Manual Auto Switch (AUTO)

5. Verify that the

all

status LED on the MPEC display are

"OFF" (not lit).

6. Remove all loads from the generator.

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.

DCA-600SSK — GENERATOR SHUT-DOWN PROCEDURE

NOTE

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

NEVER stop the engine suddenly except in an

emergency. DO NOT use the emergency stop switch as

a method of shutting down the generator. This switch is

ONLY to be used in the event of an emergency.

WARNING - EMERGENCY STOP SWITCH

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

Use Table 14 shown below as a general checklist to be

performed on a daily basis.

DCA-800SSK — MAINTENANCE

.41ELBAT

ECNANETNIAM/NOITCEPSNI

srH01

YLIAD srH052 srH005 srH0001

ENIGNE

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

tnalooCkcehCdnarotaidaRnaelC

leveLnoitcetorP

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

M3revOecnatsiseRnoitalusnIerusaeM

smho

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

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

DCA-800SSK — MAINTENANCE

General Inspection

Prior to each use, the generating set should be cleaned and

inspected for deficiencies. Check for loose, missing or

damaged nuts, bolts or other fasteners. Also check for fuel

or oil leaks.

Air Cleaner

Every

50 hours

: If dust indicator is RED, clean the air cleaner

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.cm2,

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.

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.

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

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.

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

14. Drain the water inside reserve tank, clean the inside of

the reserve tank, then fill with coolant/water mixture to

between the full and low lines.

15. Stop the engine, wait for 3 minutes, add tap water until

the water 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.

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.

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.

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 — MAINTENANCE

Allow engine to

cool

when flushing out

radiator. Flushing the radiator while hot

could cause serious burns from water or

steam.

WARNING - BURN HAZARDS

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

Generator Storage:

For storage of the generator for over 30 days, the following

is required:

Fill the fuel tank completely. 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.

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.

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

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).

DCA-800SSK — MAINTENANCE

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

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

jacket water heate

r and i

nternal

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

hot

climates there is no reason

to apply power to jacket water heater. However, if the

generator will be used in

cold

climates it is always a good

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.

DCA-800SSK — MAINTENANCE

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.

To ensure adequate starting

capability, always have power

applied to the generator's

internal battery charger

NOTE

Figure 75. Battery Charger/Jacket Water

Heater Power Connections

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

Figure 76. Hydraulic Brake Components

Brakes

Trailer brakes should be inspected the

first 200 miles

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

qualified

and

trained technicians

S-Cam Brakes

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

turns the s-cam (so called because it is shaped like the

letter "S").

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,

letting the wheels roll freely.

Air Tank Drains

Compressed air usually has some water in it which is

bad

for the air brake system. Water can freeze in cold weather

and thus cause brake failure. The water tends to collect in

the bottom of the air tank.

Daily air tank drainage is required

to remove water from the air tank

Brake Drums (or discs), Linings, and Hoses

Brake drums or discs must not have cracks longer than one

half the width of the friction area. Linings must not be loose,

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.

Air Leaks

Always check for brake air leaks before towing the trailer.

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

possibility exists of brake failure.

NOTE

Use Table 15 as a basic

troubleshooting guide when

brake problems occur.

DCA-800SSK — MAINTENANCE

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

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.

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

hot!

. Check inflation

pressure weekly during use to insure the maximum tire life

and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

ALWAYS

wear safety glasses

when removing or installing force

fitted parts. Failure to comply

may result in serious injury.

Suspension

The

leaf suspension

springs and associated components

(Figure 77) should be visually inspected

every 6,000

miles

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.

Figure 77. Major Suspension Components

DCA-800SSK —TRAILER MAINTENANCE

NOTE

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.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS

wear safety glasses when

removing or installing force fitted parts.

Failure to comply may result in serious

injury.

CAUTION - EYESIGHT HAZARD

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

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.

Figure 78. Wheel Lug Nuts Tightening Sequence

DCA-800SSK —TRAILER MAINTENANCE

NOTE

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Use a

torque wrench

to tighten

lug nuts.

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"5152-0206-05021-09

"6152-0206-05021-09

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 59

DCA-800SSK — TRAILER-WIRING DIAGRAM

Figure 79. Trailer Wiring Diagram (5-Pin)

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

DCA-800SSK — TRAILER-WIRING DIAGRAM

Figure 80. Trailer Wiring Diagram (7-Pin)

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

DCA-800SSK — GENERATOR WIRING DIAGRAM

Figure 81. Generator Wiring Diagram

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

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

Figure 82. Main Circuit Breaker Wiring Diagram

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

DCA-800SSK — ENGINE WIRING DIAGRAM

Figure 83. Engine Wiring Diagram

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

DCA-800SSK — ENGINE WIRING DIAGRAM

Figure 84. Engine Wiring Diagram(Continued)

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 65

DCA-800SSK — ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM

Figure 85. Electronic Governor Controller

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

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

tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

woltalioenigneroleuf

?erutarepmet

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip .ecalperroriapeR

morfkaelnoisserpmoC

?rednilyc

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

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

DCA-800SSK — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tonsinoituloverenignE .htooms

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

?erusserp .tsujdA

rokcutselzzonnoitcejnI

?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?kcuts .ecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

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

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

tuptuOegatloVoN

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC

?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

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

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

thgilerusserpliowoL

.nosi

?levelliowoL.levelliolliF

?eruliaftinugnidneserusserpliO .tinugnidneserusserplio

ecalpeR

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?detrohseriW.eriwriaper/tcepsnI

thgilleveltnaloocwo

.nosi

?leveltnaloocwoL.leveltnalooclliF

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yretta

begrahc/ecalpeR

tnaloochgiH

.nosithgilerutrepmet

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaida

rhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytlu

afrosteksagriaper/ecalpeR

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

.nosithgilknarcr

evO

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenrellortnoC.relaedotrefeR

.nosithgildeepsrevO

?hgihootdee

psenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellor

tnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

ro)s(thgilUPMfo

ssoL

.no

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipcitengaM .pukcipcitengamnaelC

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

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.

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

(@, #, +, %, 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.

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.

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.

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.

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)”

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.

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

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 — SUGGESTED SPARE PARTS

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

GENERATOR ASSY.

DCA-800SSK — GENERATOR ASSY.

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

DCA-800SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY.REMARKS

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

1-1*FIELD ASSY. 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

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

DCA-800SSK — GENERATOR ASSY.

GENERATOR ASSY.

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

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

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

DCA-800SSK — CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

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

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

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

DCA-800SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

DCA-800SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY.REMARKS

1C5214000002 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

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

DCA-800SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

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

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

DCA-800SSK — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

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

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

DCA-800SSK — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

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

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

DCA-800SSK — OIL DRAIN ASSY.

OIL DRAIN ASSY.

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

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

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

DCA-800SSK — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 89

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 SLEEVE ........................................................ 4 ..... UP TO S/N 3702700

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~

PAGE 90 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 91

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

PAGE 92 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

OUTPUT TERMINAL ASSY.

DCA-800SSK — OUTPUT TERMINAL ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 93

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/* UPTO S/N 3706720

31 G5261600204 BRACKET, CIRCUIT BREAKER .................... 1 .........INCLUDES ITEMS W/# S/N 3706721~

32*0223300150 RUBBER CUSHION ....................................... 1 .........UP TO S/N 3706720

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~

DCA-800SSK — OUTPUT TERMINAL ASSY.

PAGE 94 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — BATTERY ASSY.

BATTERY ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 95

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

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

MUFFLER ASSY.

DCA-800SSK — MUFFLER ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 97

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

PAGE 98 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

FUEL TANK ASSY.

DCA-800SSK — FUEL TANK ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 99

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

PAGE 100 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 101

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY.REMARKS

1 C5414000002 BASE 1

2 7525116004 FLOOR PANEL 1

3 0019110030 HEX. HEAD BOLT 4

3 0042310000 LOCK WASHER 4

3 0042410000 PLAIN WASHER 4

4 C5414100004 FLOOR PANEL 1

5 0019208020 HEX. HEAD BOLT 12

6 C5414600004 GUIDE PANEL, AIR 1

7 0017108020 HEX. HEAD BOLT 4

8 C5424001303 FRONT FRAME 1

8 C5494100003 LINING 1

9 C5424000803 FRONT FRAME 1

9 C5494100003 LINING 1

10 C5424000003 FRONT FRAME 1

11 0017108020 HEX. HEAD BOLT 6

12 C5424000202 FRONT FRAME 1

12 C5494100003 LINING 1

13 C5424000302 FRONT FRAME 1

13 C5494100003 LINING 1

14 0017108020 HEX. HEAD BOLT 26

15 C5424000603 GUIDE PANEL, AIR 1

15 C5494100003 LINING 1

16 C5424000403 GUIDE PANEL, AIR 1

16 C5494100003 LINING 1

17 C5424000503 GUIDE PANEL, AIR 1

17 C5494100003 LINING 1

18 0017108020 HEX. HEAD BOLT 36

19 C5424000704 GUSSET 2

20 0017110025 HEX. HEAD BOLT 8

21 C5327100003 BREATHER PIPE 1

22 0017110025 HEX. HEAD BOLT 2

23 0019210025 HEX. HEAD BOLT 10

24 7525125403 COVER, FRONT FRAME 1

25 7525125103 COVER, FRONT FRAME 1

25 C5494100304 LINING 1

26 0019208020 HEX. HEAD BOLT 36

27 0845042703 FILLER BRACKET 1

28 0019208020 HEX. HEAD BOLT 4

29 7525125304 COVER 1

30 0019106020 HEX. HEAD BOLT 6

30 0042306000 LOCK WASHER 6

30 0042406000 PLAIN WASHER 6

DCA-800SSK — ENCLOSURE #1 ASSY.

PAGE 102 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 103

DCA-800SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY.REMARKS

31 C5424200103 COVER, FRONT FRAME 1

32 C5424200203 COVER, FRONT FRAME 1

33 0019208020 HEX. HEAD BOLT 16

34 C5434000002 CENTER FRAME 1

35 0010120075 HEX. HEAD BOLT 6

35 0030020000 HEX. NUT 6

35 0040020000 LOCK WASHER 6

35 0041220000 PLAIN WASHER 6

36 0010120065 HEX. HEAD BOLT 10

36 0030020000 HEX. NUT 10

36 0040020000 LOCK WASHER 10

36 0041220000 PLAIN WASHER 10

37 C5434200003 COVER 2

38 0207008000 HEX. NUT 8

39 C5464100203 ROOF PANEL ........................................... 1 .........UP TO S/N 3707480

39 C5464100903 ROOF PANEL ........................................... 1 .........S/N 3707481~

40 C5464100003 ROOF PANEL ........................................... 1 .........UP TO S/N 3707480

40 C5464100703 ROOF PANEL ........................................... 1 .........S/N 3707481~

41 C5464100103 ROOF PANEL ........................................... 1 .........UP TO S/N 3707480

41 C5464100103 ROOF PANEL ........................................... 1 .........S/N 3707481~

42 0207008000 HEX. NUT 14

43 0800251701 FILLER COVER 1

44 0019206016 HEX. HEAD BOLT 2

45 0019208020 HEX. HEAD BOLT 12

46 0019210025 HEX. HEAD BOLT 20

47 0600500090 EMBLEM 1

48 0021106016 MACHINE SCREW 2

49 C5464500004 BRACKET ................................................ 2 ......... S/N 3707481~

PAGE 104 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

ENCLOSURE #2 ASSY.

DCA-800SSK — ENCLOSURE #2 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 105

ENCLOSURE #2 ASSY.

NO PART NO PART NAME QTY.REMARKS

1 C5444000313 REAR FRAME 1

1 C5494300104 LINING 1

2 7525151004 LOUVER PANEL 5

3 0207006000 NEX. NUT 40

4 C5444000203 REAR FRAME 1

4 C5494300004 LINING 1

5 C5444000003 REAR FRAME 1

5 C5494300004 LINING 1

6 C5444400103 REAR FRAME 1

6 C5494300004 LINING 1

7 0017110025 HEX. HEAD BOLT 23

8 0019210025 HEX. HEAD BOLT 4

9 7525155403 COVER, REAR FRAME 1

9 7525944304 LINING 1

10 7525151804 LOUVER PANEL 1

11 0205006000 HEX. NUT 21

11 0042306000 LOCK WASHER 21

11 0042406000 PLAIN WASHER 21

12 C5444300004 DUCT COVER 1

12 C5494300204 LINING 1

13 0017108020 HEX. HEAD BOLT 15

14 0019208020 HEX. HEAD BOLT 21

15 C5444300303 VISOR 1

16 7525165603 VISOR 1

17 0019208020 HEX. HEAD BOLT 13

18 C5444200113 DOOR, REAR FRAME 1

19 C5444200003 DOOR, REAR FRAME 1

20 7525147014 WINDOW PLATE 1

21 7525147114 WINDOW PLATE 1

22 0207306000 HEX. NUT 14

23 B9114000102 DOOR HANDLE 1

24 0021806016 MACHINE SCREW 4

25 7525146404 DOOR ROD 1

26 7525146504 DOOR ROD 1

27 0845050704 STAY 4

28 0205006000 HEX. NUT 8

28 0042306000 LOCK WASHER 8

28 0042406000 PLAIN WASHER 8

DCA-800SSK — ENCLOSURE #2 ASSY.

PAGE 106 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 107

DCA-800SSK — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO PART NO PART NAME QTY.REMARKS

29 0805011304 STOPPER, DOOR 1

30 0805011204 STOPPER, DOOR 1

31 0205006000 HEX. NUT 4

31 0042306000 LOCK WASHER 4

31 0042406000 PLAIN WASHER 4

32 M9110100204 HINGE ...................................................... 2 .........REPLACES 0845047104

32 0845045004 WASHER 2

33 M9110100304 HINGE ...................................................... 2 .........REPLACES 0845047204

33 0845045004 WASHER 2

34 0019208020 HEX. HEAD BOLT 4

35 0845031504 CAP 4

36 0601850097 STOPPER 4

37 0021008025 MACHINE SCREW 4

38 C5464200203 ROOF PANEL 1

38 C5494500003 LINING 1

39 C5464200003 ROOF PANEL ........................................... 1 .........UP TO S/N 3707480

39 C5464200103 ROOF PANEL ........................................... 1 .........S/N 3707481~

39 C5494500003 LINING 1

40 C5464200103 ROOF PANEL ........................................... 1 .........UP TO S/N 3707480

40 C5464200803 ROOF PANEL ........................................... 1 .........S/N 3707481~

40 C5494500003 LINING 1

41 0207008000 HEX. NUT 18

42 C5464200504 PANEL 1

42 C5494500003 LINING 1

43 C5464200604 GUIDE 1

44 0207008000 HEX. NUT 20

45 0017108020 HEX. HEAD BOLT 4

46 C5464200404 PANEL 1

46 C5494500003 LINING 1

47 C5464200304 PANEL 1

47 C5494500003 LINING 1

48 0207008000 HEX. NUT 10

49 0017108020 HEX. HEAD BOLT 4

50 C5464400004 COVER, ROOF PANEL 1

50 C5494500104 LINING 1

51 0017108020 HEX. HEAD BOLT 12

52 0019210025 HEX. HEAD BOLT 34

53 0019112030 HEX. HEAD BOLT 4

53 0042312000 LOCK WASHER 4

53 0042412000 PLAIN WASHER 4

54 0600500090 EMBLEM 1

55 0021106016 MACHINE SCREW 2

56 B9114500104 DOOR POCKET 1

57 0207006000 HEX. NUT 4

58 C5464500104 BRACKET ................................................ 1 ......... S/N 3707481~

59 C5464500204 BRACKET ................................................ 1 ......... S/N 3707481~

PAGE 108 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

ENCLOSURE #3 ASSY.

DCA-800SSK — ENCLOSURE #3 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 109

ENCLOSURE #3 ASSY.

NO PART NO PART NAME QTY.REMARKS

1 C5454200403 SPLASHER PANEL .................................. 1 ......... S/N 3692434 TO 3700698

1 C5454200413 SPLASHER PANEL .................................. 1 ......... S/N 3700699 TO 3706720

1 C5454200423 SPLASHER PANEL .................................. 1 .........S/N 3706721~

2 0019110070 HEX. HEAD BOLT 6

2 0042310000 LOCK WASHER 6

2 0042410000 PLAIN WASHER 6

3 C5454100003 SIDE PANEL 1

3 C5494400004 LINING 1

4 C5454100103 SIDE PANEL 1

4 C5494400104 LINING 1

5 7525173803 SIDE PANEL 1

5 7525972504 LINING 1

6 7525173903 SIDE PANEL 1

6 7525972704 LINING 1

7 7525173203 SIDE DOOR 1

7 7525970904 LINING 1

8 7525173303 SIDE DOOR 1

8 7525971104 LINING 1

9 7525173403 SIDE DOOR 1

9 7525971304 LINING 1

10 7525173503 SIDE DOOR 1

10 7595971504 LINING 1

11 7525151004 LOUVER PANEL 2

12 7525151604 LOUVER PANEL 1

13 7525151704 LOUVER PANEL 1

14 7525151304 LOUVER PANEL 2

15 7525151404 LOUVER PANEL 1

16 7525151504 LOUVER PANEL 1

17 0205006000 HEX. NUT 75

17 0042306000 LOCK WASHER 75

17 0042406000 PLAIN WASHER 75

18 7435176204 DUCT 2

18 C5494400204 LINING 2

19 7525176504 DUCT 1

19 7525966904 LINING 1

20 7525176604 DUCT 1

20 7525967104 LINING 1

21 7525176004 DUCT 1

21 7525967304 LINING 1

22 C5454300004 DUCT 1

22 C5497400004 LINING 1

23 7525176004 DUCT 1

23 7525966504 LINING 1

DCA-800SSK — ENCLOSURE #3 ASSY.

PAGE 110 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — ENCLOSURE #3 ASSY.

ENCLOSURE #3 ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 111

DCA-800SSK — ENCLOSURE #3 ASSY.

ENCLOSURE #3 ASSY.

NO PART NO PART NAME QTY.REMARKS

24 7525176704 DUCT 1

24 7525966704 LINING 1

25 0019208020 HEX. HEAD BOLT 58

26 0825007362 DOOR HANDLE 3

27 0021806016 MACHINE SCREW 12

28 0845046904 HINGE 11

28 0845045004 WASHER 11

29 0845047004 HINGE 11

29 0845045004 WASHER 11

30 0019208020 HEX. HEAD BOLT 52

31 0845031504 CAP 22

32 0601850097 STOPPER 15

33 0021008025 MACHINE SCREW 15

34 0019110070 HEX. HEAD BOLT 8

34 0042310000 LOCK WASHER 8

34 0042410000 PLAIN WASHER 8

35 B9114000002 DOOR HANDLE 4

36 0021806016 MACHINE SCREW 16

37 0019110055 HEX. HEAD BOLT 2

37 0042310000 LOCK WASHER 2

37 0042410000 PLAIN WASHER 2

PAGE 112 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 113

DCA-800SSK — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0228901690 RUBBER SEAL 8

2 0228900995 RUBBER SEAL 4

3 0228901035 RUBBER SEAL 4

4 0228901090 RUBBER SEAL 2

5 0229201950 RUBBER SEAL 2

6 0228801030 RUBBER SEAL 2

7 0228801590 RUBBER SEAL 2

8 0229200710 RUBBER SEAL 2

9 0229201840 RUBBER SEAL 1

10 0229200625 RUBBER SEAL 2

11 0229201840 RUBBER SEAL 1

12 0228100380 RUBBER SEAL 2

13 0228100550 RUBBER SEAL 2

14 0228100120 RUBBER SEAL 2

15 0228100580 RUBBER SEAL 2

16 0228901000 RUBBER SEAL 2

PAGE 114 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — NAME PLATE AND DECALS

NAME PLATE AND DECALS

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 115

DCA-800SSK — NAME PLATE AND DECALS

NAME PLATE AND DECALS

NO PART NO PART NAME QTY.REMARKS

CONTROL PANEL GROUP

1 0800520904 PLATE; ON-OFF ............................................ 1 ....... AT-202

2 0800520904 PLATE; AMMETER CHANGE-OVER

SWITCH ........................................................ 1 ....... N-2438

3 0800520814 PLATE; VOLTMETER CHANGE-OVER

SWITCH ........................................................ 1 ....... N-2439

4 0800564004 PLATE; OFF .................................................. 2 ....... N-3805

5 0800565004 PLATE; ON .................................................... 2 ....... N-3806

6 0800588004 PLATE; THROTTLE LEVER .......................... 1 ....... N-3808 ...... UP TO S/N 3693885

7 0840624504 DECAL; CIRCUIT BREAKER ........................ 2 ....... S-3031

8 0840624604 DECAL; PANEL LIGHT SWITCH ................... 1 ....... S-3032

9 0840624704 DECAL; PILOT LAMP ................................... 1 ....... S-3033

10 0840624804 DECAL; VOLTAGE REGULATOR ................... 1 ....... S-3034

11 B9531100604 DECAL; WARNING ELECTRIC SHOCK

HAZARD ........................................................ 1 ....... B93110060

12 C5551000303 DECAL; SETTING FOR OUTPUT VOLTAGE 1 ....... C55100030

13 C5561100903 DECAL; WHISPERWATT 800 ........................ 1 ....... C56110090

14 Z0110001204 DECAL; DROOP ............................................ 1 ....... Z01000120

15 Z0110001304 DECAL; IDLE SPEED ................................... 1 ....... Z01001230

16 Z0110001404 DECAL; O.S.SW ............................................ 1 ....... Z01000140

17 Z0110001504 DECAL; RESET ............................................ 1 ....... Z01000150

ENGINE OPERATING PANEL GROUP

18 0800686004 DECAL; STOP BUTTON ................................ 1 ....... S-878

19 0840625004 DECAL; PREHEAT LAMP ............................. 1 ....... S-3036

20 0840625104 DECAL; STARTER SWITCH .................................... S-3037

21 0840625314 DECAL; AIR CLEANER INDICATOR ............. 1 ....... S-3039A

22 9039208694 DECAL; HIGH-LOW ....................................... 1 ....... S-4451

23 9039208704 DECAL; ENGINE SPEED ............................. 1 ....... S-4452

24 0840655604 DECAL; ALARM, OIL FILTER ....................... 1 ....... S-4512

25 C0551000504 DECAL; BATTERY SWITCH .......................... 1 ....... C05120050

PROCEDURE GROUP

26 C5552000003 DECAL; HANDLING PROCEDURES ............. 1 ....... C55200000 UP TO S/N 3693885

26 C5552000012 DECAL; HANDLING PROCEDURES ............. 1 ....... C55200001 UP TO S/N 3698625

26 C1552000403 DECAL; HANDLING PROCEDURES ............. 1 ....... C15200040 S/N 3698626~

27 B9521100404 DECAL; SAFETY INSTRUCTIONS ..................... 1 ........ B92110040

28 B1552000103 DECAL: CAUTION ............................................... 1 ........ B15200010 S/N 3698626~

PAGE 116 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

DCA-800SSK — NAME PLATE AND DECALS

NAME PLATE AND DECALS

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 117

DCA-800SSK — NAME PLATE AND DECALS

NO PART NO PART NAME QTY.REMARKS

ENGINE & RADIATOR GROUP

29 0800689204 DECAL; COOLING WATER ................................. 1 ........ S-961

30 B9504000304 DECAL; CAUTION HOT PARTS ......................... 1 ........ B90400030

31 B9504000404 DECAL; WARNING MOVING PARTS .................. 2 ........ B90400040

32 B9504100104 DECAL; WARNING HOT COOLANT .................. 1 ........ B90410010

33 0966810000 DECAL; WARNING .............................................. 1 ........ REPLACES 0600501100

34 6162937111 DECAL; FUEL PRIMING ...................................... 1 ........ REPLACES 0600500011

OIL DRAIN GROUP

35 0840611903 DECAL; PRECAUTIONS ON HANDLING ........... 1 ........ S-2570

OUTPUT TERMINAL GROUP

36 0840614104 DECAL; GROUND ............................................... 1 ........ S-2635

37 9039202064 DECAL; START CONTACT ................................. 1 ........ S-4468

38 0840655704 DECAL; TERMINAL COVER STOPPER ............. 1 ........ S-4516

39 B9511100304 DECAL; WARNING .............................................. 1 ........ B91110030

40 B9511100404 DECAL; WARNING ELECTRIC SHOCK

HAZARD .............................................................. 1 ........ B91110040

41 B9531100504 DECAL; WARNING ELECTRIC SHOCK

HAZARD .............................................................. 1 ........ B93110050

42 C0551000404 DECAL; 3-PHASE OUTPUT TERMINAL ............ 1 ........ C05100040

43 C5551000203 DECAL; RECEPTACLE & CIRCUIT BREAKER .. 1 ........ C55100020 S/N 3692434 TO 3706720

44 C5551000403 DECAL; RECEPTACLE & CIRCUIT BREAKER .. 1 ........ C55100040 S/N 3706721~

BATTERY GROUP

44 0800689404 DECAL; + .............................................................. 1 ........ S-2090

45 0800689504 DECAL; - ............................................................... 1 ........ S-2091

46 C9505300004 DECAL: CAUTION ............................................... 1 ........ C90530000 S/N 3698626~

MUFFLER GROUP

47 B9504200004 DECAL; WARNING ENGINE EXHAUST .............. 1 ....... B90420000

48 B9511100204 DECAL; CAUTION HOT SURFACES ................... 1 ....... B91110020

FUEL TANK GROUP

50 0800688404 DECAL; FUEL INLET ........................................... 1 ........ S-1344

51 0800688504 DECAL; FUEL OUTLET ...................................... 1 ........ S-1345

52 1320620904 DECAL; DIESEL FUEL ........................................ 1 ........ S-1756

53 6360620004 DECAL; FUEL DRAIN PLUG ............................... 1 ........ S-1883

54 0840607104 DECAL; FUEL GAUGE ........................................ 1 ........ S-2365

55 B9504500004 DECAL; WARNING DIESEL FUEL ...................... 1 ........ B90450000

BONNET GROUP

56 0800615102 DECAL; CAUTION AGAINST OIL AND ............... 1 ........ S-544A

57 1320610603 DECAL; WATER-OIL ........................................... 1 ........ S-1760

58 1320621504 DECAL; SUPPORT HOOK .................................. 2 ........ S-2257

59 0840625902 DECAL; MQ .......................................................... 1 ........ S-3057

60 C5561100703 STRIPE ................................................................ 1

61 C5561100603 STRIPE ................................................................ 1 ........

62 C4561101204 STRIPE ................................................................ 2 ........

63 C5561100804 STRIPE ................................................................ 2 ........

64 C5561100204 STRIPE ................................................................ 2 ........

65 C5561100503 STRIPE ................................................................ 1 ........

66 C5561100004 STRIPE ................................................................ 2

PAGE 118 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

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 shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a

signed manifest has been obtained from the

carrier, and any claim for shortage or damage

must be settled between the consignee and

the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and

credit will be allowed, subject to the following

provisions:

A Returned Material Authorization 1.

must be approved by Multiquip prior to

shipment.

To obtain a Return Material Authorization, 2.

a list must be provided to Multiquip

Parts Sales that deﬁnes item numbers,

quantities, and descriptions of the items

to be returned.

The parts numbers and descriptions a.

must match the current parts price

list.

The list must be typed or computer b.

generated.

The list must state the reason(s) c.

for the return.

The list must reference the sales d.

order(s) or invoice(s) under

which the items were originally

purchased.

The list must include the name e.

and phone number of the person

requesting the RMA.

A copy of the Return Material Authorization 3.

must accompany the return shipment.

Freight is at the sender’s expense. All 4.

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

Parts must be in new and resalable 5.

condition, in the original Multiquip

package (if any), and with Multiquip part

numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a.

price book and shows as being

replaced by another item, it is

obsolete.)

Any parts with a limited shelf life b.

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

Any line item with an extended c.

dealer net price of less than

$5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper products.g.

Items purchased in kits.h.

The sender will be notiﬁed of any material 7.

received that is not acceptable.

Such material will be held for five 8.

working days from notiﬁcation, pending

instructions. If a reply is not received

within five days, the material will be

returned to the sender at his expense.

Credit on returned parts will be issued 9.

at dealer net price at time of the original

purchase, less a 15% restocking

charge.

In cases where an item is accepted, for 10.

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

Credit issued will be applied to future 11.

purchases only.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a

speciﬁc date and all orders received on or

after that date will be billed at the revised price.

Rebates for price declines and added charges

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and

sell direct to Government agencies, and to

Original Equipment Manufacturer accounts

who use our products as integral parts of their

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the

invoice for special handling including bus

shipments, insured parcel post or in cases

where Multiquip must personally deliver the

parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder for

damages in excess of the purchase price of

the item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of proﬁt or good will or for any

other special, consequential or incidental

damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are

made in connection with the sale of parts or

trade accessories nor as to any engine not

manufactured by Multiquip. Such warranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes nor

authorizes any person to assume for it

any other obligation or liability whatever in

connection with the sale of its products. Apart

from such written statement of warranty,

there are no warranties, express, implied or

statutory, which extend beyond the description

of the products on the face hereof.

Effective: February 22, 2006

DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 119

NOTE PAGE

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

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the

property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in

this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁcations, design or the information published

in this publication at any time without notice and without incurring any obligations.

Further, MQ Power disclaims any warranties or guaranties, expressed or implied, with regards to the information contained in this manual. Manufactured for

Multiquip Inc.

DENYO CO., LTD, JAPAN

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave Tel. (800) 421-1244

Carson, CA 90746 Fax (800) 537- 3927

Contact: mq@multiquip.com

Web: www.multiquip.com

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551

Suite 500/600 Fax (972) 315-1847

Lewisville, TX 75057

Contact: mqpower@multiquip.com

Web: www.mqpower.com

MQ Parts Department

800-427-1244 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Service/Tech Support/Warranty

800-835-2551 Fax: 310-638-8046

Multiquip Portabel Generator Standard Dca 800Ssk Users Manual DCA800SSK Rev 4 060310

MQ Power WhisperWatt 800 Generator DCA800SSK Generators_portable_whisperwatt_DCA800SSK_rev_4_std_manual_DataId_19118_Version_1

DCA-800SSK to the manual ab06fc7c-0b5d-44ed-9c9e-a183bb953639

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