MQ Power WhisperWatt DCA800SSK Operation And Parts Manual Download Page 2

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

Diesel engine exhaust and some of

Summary of Contents for WhisperWatt DCA800SSK

Page 1: ...HE EQUIPMENT AT ALLTIMES 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: ...PAGE 2 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 Diesel engine exhaust and some of ...

Page 3: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 3 ...

Page 4: ... 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 TrailerWiring Diagrams 59 60 GeneratorWiring Diagram 61 Generator Main breakerWiring Diagram 62 EngineWiring Diagrams 63 ...

Page 5: ...bsite 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...

Page 6: ...0 6 d e e p S m p r 0 0 8 1 r o t c a F r e w o P 8 0 A B d l e v e L d n u o S t e e f 3 2 t a d a o l l l u f 3 7 s n o i t a c i f i c e p S e n i g n E l e d o M 0 4 1 V 2 1 V S U S T A M O K e p y T r e l o o c r e t f a h t i w d e g r a h c o b r u t n o i t c e j n i t c e r i d s r e d n i l y C f o o N s r e d n i l y c 2 1 e k o r t S x e r o B m m 5 6 1 x m m 0 4 1 n i 5 6 x n i 5 5 t ...

Page 7: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 7 NOTE PAGE ...

Page 8: ...PAGE 8 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK DIMENSIONS TOP AND SIDE Figure 1 Dimensions ...

Page 9: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 9 Figure 2 Dimensions DCA 800SSK DIMENSIONS FRONT REAR AND DOORS ...

Page 10: ...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 ...

Page 11: ...vironment 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 HAZ...

Page 12: ...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 READTHIS MANUAL ALWAYS check the machine for loosened threads or bolts before starting NEVERoperatethegeneratorinanexplosiveatmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death N...

Page 13: ...equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC providesguidelinesforpropergroundingandspecifies 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 groun...

Page 14: ...h 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...

Page 15: ...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 ar...

Page 16: ...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 ...

Page 17: ...ning 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 A...

Page 18: ...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...

Page 19: ...hmaximumpound 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 conne...

Page 20: ...U S S B L 0 0 0 7 g K 5 7 1 3 s e h c n i 8 3 1 s r e t e m 0 5 3 s e h c n i 6 6 s r e t e m 7 6 1 g K 7 0 9 S B L 0 0 0 2 D A P T A L F F X 0 7 R L R T 0 7 0 6 5 4 A C D s n o l l a G 3 5 s r e t i L 1 0 2 E G R U S S B L 0 0 0 7 g K 5 7 1 3 s e h c n i 8 3 1 s r e t e m 0 5 3 s e h c n i 6 6 s r e t e m 7 6 1 g K 7 0 9 S B L 0 0 0 2 D A P T A L F F X 0 0 1 R L R T 5 2 1 0 0 1 A C D s n o l l a ...

Page 21: ... l 0 0 5 3 3 G U L 5 F A E L 5 T A L F R E B B U R E L O P 4 X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 T A L F R E B B U R E L O P 4 F X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 T A L F R E B B U R E L O P 4 F X 0 0 1 R L R T T P O 6 5 2 E L B A...

Page 22: ...h 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 ...

Page 23: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 23 DCA 800SSK OPERATION AND SAFETY DECALS ...

Page 24: ...PAGE 24 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK OPERATION AND SAFETY DECALS ...

Page 25: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 25 DCA 800SSK OPERATION AND SAFETY DECALS ...

Page 26: ...tationary 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...

Page 27: ...T P I R C S E D 1 y l b m e s s A r o t a r e n e G 2 y l b m e s s A l e n a P l o r t n o C r o t a r e n e G 3 y l b m e s s A r o t a i d a R d n a e n i g n E 4 y l b m e s s A l e n a P g n i t a r e p O e n i g n E 5 y l b m e s s A y r e t t a B 6 y l b m e s s A e r u s o l c n E 7 y l b m e s s A k n a T l e u F 8 y l b m e s s A r e l f f u M 9 y l b m e s s A l a n i m r e T t u p t u ...

Page 28: ...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 ...

Page 29: ...l shut down the generator A Off Manual AutoSwitch Thisswitchcontrolstherunning 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 Ifthegeneratoristobeconnectedtoabuilding sACpower source via a transfer switch isolation place the switch in the autoposition In this position the gen...

Page 30: ...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 ...

Page 31: ...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 mustbeservicedorreplaced Thisengineofthisgenerator requires two air cleaners 2 Battery Switch This switch should be set to the ON position during normal operation When the engine has been...

Page 32: ...ed 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 OutputTerminal Panel lift up on the cover to gain access to receptacles and terminal lugs Terminal legs O and Ground are considered bonded grou...

Page 33: ...ee 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 increasethevoltage turningtheknobcounter clockwise will decrease the voltage Figure 10 240 139 VAC Twist Lock Auxiliary Receptacles Twist Lock DualVoltage 240 139VAC Receptacles There are thre...

Page 34: ...r is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Over Current Relay An 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 curren...

Page 35: ... VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Three Phase Load Whencalculatingthepowerrequirementsfor3 phasepower 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 SeeTable5 NOTE n o i t a r e p O e s...

Page 36: ... 2 V 0 8 4 0 4 8 0 2 0 2 1 4 0 1 0 6 0 0 1 9 1 5 1 0 3 1 6 2 0 5 1 0 6 1 1 3 8 1 8 4 7 1 4 1 4 2 0 2 2 2 4 1 1 2 6 6 3 7 5 1 3 3 0 8 2 4 5 4 1 2 4 8 0 3 7 1 2 4 0 4 3 5 6 7 1 2 2 0 1 6 8 8 1 1 5 0 0 4 7 7 0 2 3 0 2 1 2 4 0 1 1 0 6 0 6 4 8 8 3 2 3 8 3 1 9 9 1 1 2 9 6 0 2 5 0 0 7 2 4 6 5 1 5 5 3 1 2 8 7 0 8 5 1 1 0 3 4 4 7 1 1 1 5 1 2 7 8 0 4 6 3 2 3 3 5 2 9 1 7 6 6 1 2 6 9 Ø 3 s g n i t a R e r e p...

Page 37: ... on the selected leg The ammeter and voltmeter gauges areonlyactivewhenthe 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 A 0 40 60 75 20 Figure 20 AC Am...

Page 38: ...ed voltage 3Ø 240V UVWOTerminal OutputVoltages 1 Jumperthevoltagechange overboardfor240Voperation 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...

Page 39: ...e 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 UVWOTerminal OutputVoltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 26 2 ConnecttheloadwirestotheUVWOterminalsasshown in Figure 29 Figure 29 UVWO Terminal Lugs 1Ø 277V Connections ALWAYS...

Page 40: ...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 T...

Page 41: ...Filling Order Figure 33 Only Fill on Level Ground ONLY use 2 diesel fuel when refueling NOTE 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 REFUELINGTHE GENERATOR Ref...

Page 42: ...ow the trailer filler tube level rises when the internal tank is filled 5 Figure 37 below reflects a full fuel system 6 Fuelfromtheenginereturnlinewilldrainintothesecondary 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 Fig...

Page 43: ...us 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 BeltTension 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 Komats...

Page 44: ...e fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe 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 ...

Page 45: ...re 41 Engine Operating Panel UpTo S N 3699247 1 Placethemain G F C I andaux circuitbreakers Figure42 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...

Page 46: ... 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 r...

Page 47: ...48 willindicate 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 0 4 8 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 Fi...

Page 48: ...tch 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 ...

Page 49: ...e 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...

Page 50: ...ed Switch High 3 Let the engine cool by running it for 3 5 minutes with no loadapplied 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 ...

Page 51: ... d n a l i O e n i g n E e c a l p e R 1 X r e t l i F r i A n a e l C X k n a T l e u F f o m o t t o B n i a r D X e d i s t u O d n a e d i s n I t i n U n a e l C X r e t l i F l e u F e g n a h C 2 X t n a l o o C k c e h C d n a r o t a i d a R n a e l C l e v e L n o i t c e t o r P X t n e m e l E r e t l i F r i A e c a l p e R X r o t s i s e R n o i s o r r o C e g n a h C X s p m a l C...

Page 52: ...ccording to season and locations Always pour through the mesh filter RemovingWater from theTank 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 ...

Page 53: ...ter 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 ca...

Page 54: ...ne 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 Corro...

Page 55: ...ot 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...

Page 56: ... 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 basi...

Page 57: ...nstallingforce 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 Susp...

Page 58: ...tening Sequence DCA 800SSK TRAILER MAINTENANCE NOTE NEVER use an pneumatic air gun to tighten wheel lug nuts Useatorquewrenchtotighten lug nuts s t n e m e r i u q e R e u q r o T n o i s n e p s u S 7 1 e l b a T m e t I s b L t F e u q r o T T L O B U 8 3 5 3 X A M 0 3 N I M T L O B U 6 1 7 0 6 X A M 5 4 N I M T L O B U 2 1 0 6 X A M 5 4 N I M SHACKLE BOLT SPRING EYE BOLT SNUG FIT ONLY PARTS MUS...

Page 59: ...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: ...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 ...

Page 61: ...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: ...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 ...

Page 63: ...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: ...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 ...

Page 65: ...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: ...w o l h t i w l e u F l e u f d e i f i c e p s e h t e s U n o i t c e j n i e s o o l o t e u d k a e l l e u F t u n g n i n i a t e r e p i p t u n n e t h g i T g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n r o w t f a h s m a c l e u F e c a l p e R d e g g o l c e l z z o n n o i t c e j n I e l z z o n n o i t c e j n i n a e l C g n i n o i t c n u f l a m p m u p n o i t ...

Page 67: ... i f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m o c t n e i c i f e D e c n a r a e l c p o t t s u j d A y a r g k r a d r o k c a l b r e h t i E d e v r e s b o s i s a g t s u a h x e d a o l r e v O d a o l e h t n e s s e L d e s u l e u f...

Page 68: ... R V A s I y r a s s e c e n f i e c a l p e R r e i f i t c e R g n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g n e s I h g i H o t r e v e l e l t t o r h t e n i g n e n r u T e s o o l s n o i t c e n n o c g n i r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r a s s e c e n f i e c a l...

Page 69: ...h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r o t a i d a r r i a p e r n a e l C n e p o s r o o D s r o o d e s o l C g n i k a e l t s u a h x E t r a p y t l u a f r o s t e k s a g r i a p e r e c a l p e R d e d a o l r e v o g n i e b r o t a r e n e G d a o l e c u d e r k c e h C e r u l i a f t a t s o m r e h T t a t s o m r e h t e c a ...

Page 70: ...t 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 genera...

Page 71: ...GINE 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 AUTOMATICVOLTAGE REGULATOR 1 7520150704 CIRCUIT BREAKER AT25 UPTO S N 3706720 1 0601840073 RHEOSTAT VOLTAGE REGULATOR 2 0601840121 KNOB RHEOSTAT 1 0601810...

Page 72: ...PAGE 72 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 GENERATOR ASSY DCA 800SSK GENERATOR ASSY ...

Page 73: ... HEAD BOLT 10 1 12 0042524000 LOCKWASHER 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 LOCKWASHER 4 1 15 0041205000 PLAINWASHER 4 1 16 0010112020 HEX HEAD BOLT 6 1 16 0040012000 LOCKWASHER 6 1 17 060100020 BALANCING WEIGHT KIT 1 1 18 C5111500003 BEARING FLANGE 1 1 19 0070106322 BEARING 1 1 20 0080000110 SN...

Page 74: ...PAGE 74 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK GENERATOR ASSY GENERATOR ASSY ...

Page 75: ...ER 8 9 C5153300003 COVER BEARING 1 10 C5153300104 GASKET BEARING 1 11 0016308095 HEX HEAD BOLT 3 11 0040008000 LOCKWASHER 3 11 0041208000 PLAINWASHER 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 ...

Page 76: ...PAGE 76 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK CONTROL PANEL ASSY CONTROL PANEL ASSY ...

Page 77: ...00A 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 06022024...

Page 78: ...PAGE 78 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 79: ...6 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 4RDC24V 23 0601810576 PI...

Page 80: ...PAGE 80 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 81: ...42508000 SPRINGWASHER 8 S N 3706721 40 0041208000 PLAIN WASHER 8 S N 3706721 41 7521861303 CHANGE OVER BOARD VOLTAGE 1 42 C5277000004 CHANGETERMINAL 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 LOCKWASHER 20 48 0041420000 PLAINWASHER 20 49 0010110040 HEX HEAD BOLT 4 49 0040010000 LOCKWASHER 4 49 004121...

Page 82: ...PAGE 82 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 83: ...BBER SHEET 2 REPLACES 0605000098 17 0010118080 HEX HEAD BOLT 8 18 0030018000 HEX NUT 8 19 0040018000 LOCKWASHER 8 20 0041218000 PLAINWASHER 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...

Page 84: ...PAGE 84 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 85: ...3 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...

Page 86: ...PAGE 86 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK OIL DRAIN ASSY OIL DRAIN ASSY ...

Page 87: ...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: ...PAGE 88 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY ...

Page 89: ...EHEAT 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...

Page 90: ...PAGE 90 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY ...

Page 91: ... 6 0030012000 HEX NUT 24 6 0040012000 LOCKWASHER 24 6 0041212000 PLAINWASHER 48 7 C5234000004 TERMINAL 1 8 0801830904 HEX HEAD BOLT 1 9 0039320000 HEX NUT 2 10 0040020000 LOCKWASHER 3 11 0041420000 PLAINWASHER 5 12 0019112060 HEX HEAD BOLT 6 12 0042312000 LOCKWASHER 6 12 0042412000 PLAINWASHER 6 13 0601850275 GROMMET 1 14 0601815324 TERMINAL BOARD 1 15 0027104020 MACHINE SCREW 2 16 C4237101304 COV...

Page 92: ...PAGE 92 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 OUTPUT TERMINAL ASSY DCA 800SSK OUTPUTTERMINAL ASSY ...

Page 93: ...4TO 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 UPTO 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 00271040...

Page 94: ...PAGE 94 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK BATTERY ASSY BATTERY ASSY ...

Page 95: ...006504 BATTERY BOLT 4 5 0037808000 WING NUT 4 6 0040008000 LOCKWASHER 4 7 0041208000 PLAINWASHER 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 C5347...

Page 96: ...PAGE 96 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 MUFFLER ASSY DCA 800SSK MUFFLER ASSY ...

Page 97: ... 24 6 0042310000 LOCKWASHER 24 6 0042410000 PLAINWASHER 24 7 C5334000103 EXHAUST PIPE 2 7 C4334200504 GASKET 4 8 0010116070 HEX HEAD BOLT 16 8 0030016000 HEX NUT 16 8 0040016000 LOCKWASHER 16 8 0041216000 PLAINWASHER 32 9 0010116050 HEX HEAD BOLT 16 9 0040016000 LOCKWASHER 16 9 0041216000 PLAINWASHER 16 10 7522355103 OUTLET PIPE 1 11 C5335200004 GASKET 1 12 0010116070 HEX HEAD BOLT 4 12 0030016000...

Page 98: ...PAGE 98 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 FUEL TANK ASSY DCA 800SSK FUELTANK ASSY ...

Page 99: ...X NUT 2 16 0042308000 LOCKWASHER 2 17 0042408000 PLAINWASHER 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 J...

Page 100: ...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 ...

Page 101: ...00003 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 ...

Page 102: ...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 ...

Page 103: ...6 0030020000 HEX NUT 10 36 0040020000 LOCKWASHER 10 36 0041220000 PLAINWASHER 10 37 C5434200003 COVER 2 38 0207008000 HEX NUT 8 39 C5464100203 ROOF PANEL 1 UPTO S N 3707480 39 C5464100903 ROOF PANEL 1 S N 3707481 40 C5464100003 ROOF PANEL 1 UPTO S N 3707480 40 C5464100703 ROOF PANEL 1 S N 3707481 41 C5464100103 ROOF PANEL 1 UPTO S N 3707480 41 C5464100103 ROOF PANEL 1 S N 3707481 42 0207008000 HEX...

Page 104: ...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 ...

Page 105: ...0 7525151804 LOUVER PANEL 1 11 0205006000 HEX NUT 21 11 0042306000 LOCKWASHER 21 11 0042406000 PLAINWASHER 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 75...

Page 106: ...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 ...

Page 107: ...PANEL 1 S N 3707481 39 C5494500003 LINING 1 40 C5464200103 ROOF PANEL 1 UPTO 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 ...

Page 108: ...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 ...

Page 109: ...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 004230...

Page 110: ...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 ...

Page 111: ...806016 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 LOCKWASHER 8 34 0042410000 PLAINWASHER 8 35 B9114000002 DOOR HANDLE 4 36 0021806016 MACHINE SCREW 16 37 0019110055 HEX HEAD BOLT 2...

Page 112: ...PAGE 112 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK RUBBER SEALS ASSY RUBBER SEALS ASSY ...

Page 113: ...R 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: ...PAGE 114 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK NAME PLATE AND DECALS NAME PLATE AND DECALS ...

Page 115: ...AGE 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 ...

Page 116: ...PAGE 116 DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 DCA 800SSK NAME PLATE AND DECALS NAME PLATE AND DECALS ...

Page 117: ...CAL 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 B951110...

Page 118: ...oducts 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 l...

Page 119: ...DCA 800SSK STD OPERATION AND PARTS MANUAL REV 4 06 03 10 PAGE 119 NOTE PAGE ...

Page 120: ...echnical 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 ...

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