MQ Power WhisperWatt DCA800SSK User manual

© COPYRIGHT 2000, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
Revision #1 (05/14/01)
MULTIQUIPINC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX:[phone]
310-537-3700
SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX:[phone] FAX:[phone]
E-mail:[email protected] •www:multiquip.com
MQ POWER
MODEL DCA-800SSK
PORTABLE GENERATOR
(Standard)
PARTS AND OPERATION MANUAL
PARTS LIST NO. C5872300004

PAGE 2 — DCA-800SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (05/14/01)

DCA-800SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (05/14/01) — PAGE 3
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927

PAGE 4 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
TABLE OF CONTENTS
NOTE
Specification and part number
are subject to change without
notice.
Here's How To Get Help...........................................3
Table Of Contents ....................................................4
Parts Ordering Procedures ......................................5
Rules For Safe Operation .................................... 6-9
Towing ....................................................................10
Trailer Safety Guidelines ........................................11
Trailer Specifications ........................................ 12-13
Trailer Braking System ..................................... 14-15
Trailer Tires & Suspension ............................... 16-17
Trailer Wiring ..........................................................18
Trailer Air Brake Troubleshooting ...........................19
Operation And Safety Decals........................... 20-23
Specifications .........................................................24
General Information......................................... 26-27
Major Components ................................................28
Dimensions ...................................................... 30-31
Control Panel.................................................... 32-33
Engine Operating Panel ................................... 34-35
Output Terminal Panel...................................... 36-41
Installation........................................................ 42-43
Pre-Setup......................................................... 44-47
Load Application ....................................................48
Generator Start-Up Procedure (Manual)......... 49-52
Generator Start-Up Procedure (Auto) ...................53
Generator Shut-Down Procedure ..........................54
Maintenance .................................................... 56-57
Generator Wiring Diagram .....................................58
Engine Wiring Diagram .................................... 60-61
Troubleshooting (Engine)................................. 62-63
Troubleshooting (Engine/Generator) .....................64
Troubleshooting MPEC ..........................................65
Explanation Of Codes In Remarks Column ...........66
Suggested Spare Parts..........................................67
MQ Power DCA-800SSK
ACGenerator
Generator Assembly ..........................................68-71
Control Panel Assembly .....................................72-73
Control Box Assembly........................................74-77
Engine Radiator Assembly.................................78-81
Oil Drain Assembly.............................................82-83
Engine Operating Panel Assembly ....................84-85
Output Terminal Assembly .................................86-87
Battery Assembly ...............................................88-89
Muffler Assembly ...............................................90-91
Fuel Tank Assembly ...........................................92-93
Enclosures Assembly.......................................94-105
Rubber Seals .................................................106-107
Name Plate and Decals .................................108-111
Terms and Conditions Of Sale — Parts ................ 112

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 5
PARTS ORDERING PROCEDURES
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■■
■ UPS Ground Service at no charge for freight
■■
■■
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Commonnuts, bolts and washers (allitems under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
For faxed orders only
UPS
Special
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Now! DirectTOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
■■
■■
■Dealer account number
■■
■■
■Dealer name and address
■■
■■
■Shipping address (if different than billing address)
■■
■■
■Return fax number
■■
■■
■Applicable model number
■■
■■
■Quantity, part number and description of each part
■■
■■
■Specify preferred method of shipment:
•UPS Ground
•UPS Second Day or Third Day*
•UPS Next Day*
•Federal Express Priority One (please provide us with your Federal
Express account number)*
•Airborne Express*
•Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Extra Fax Discount
for Domestic USA
Dealers Only

PAGE 6 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engineorgenerator.
■ 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
generatororengineandmay
cause injury to people.The
generator engine gives off
DEADLY carbon monoxide
gas.
■ High Temperatures –Allow the engine to cool before
adding fuel or performing service and maintenance
functions.Contact with
hot components cancause serious
burns.
Failure to follow instructions in this manual
may lead to serious injury or even death!
Thisequipmentistobe operated by trained
andqualifiedpersonnelonly!Thisequipment
is for industrial use only.
Thefollowingsafety guidelinesshouldalwaysbe used when
operating the DCA-800SSK portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
readingthisentiremanual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVERoperatethisequipment without proper
protective clothing, shatterproof glasses,
steel-toedbootsandotherprotectivedevices
required by the job.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVERoperatethisequipmentunderthe
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommendedby MQPower 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.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
CAUTION:
■ Alwaysuseextremecautionwhenworkingwithflammable
liquids.When refueling, stop the engine and allow it to
cool.DO NOT smoke around or near the machine.Fire or
explosion could result from fuel vapors, or if fuel is spilled
on a hot engine.
■ NEVERoperatethegeneratorinan
explosiveatmosphereornearcombustible
materials.An explosionor firecouldresult
causing severe bodily harm or even
death.
■ Topping-off to filler port is
dangerous, as it tends to spill fuel.
■ Alwaysrefuelinawell-ventilatedarea,
away from sparks and open flames.
CAUTION:

DCA-800SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (05/14/01) — PAGE 7
■ Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building'selectrical system exceptthrough an approved
device or after building main switch is opened.
RULES FOR SAFE OPERATION
CAUTION:
■ Never use damaged or worn cables when connecting
power tools or equipment to the generator. Make sure
power connecting cables are securely connected to the
generator’s output terminals, insufficient tightening of the
terminalconnectionsmay causedamagetothe generator
and electrical shock.
CAUTION:
■ DO NOT touch or open any of the below
mentionedcomponentswhile thegenerator
is running. Always allow sufficient time for
the engine and generator to cool before
performingmaintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engineis hotwillresult inhighpressurized, boiling water
to gush out of the radiator, therefore causing severe
scalding to any persons in the general area of the
generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
CAUTION:
CAUTION:
■ NEVER touch output terminals during operation.This is
extremely dangerous.
Always stop the machine when
contact with the output terminals.

PAGE 8 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
■ NEVER Run engine without air filter.Severe engine damage
may occur.
■ Always service air cleaner frequently to prevent carburetor
malfunction.
■ Always disconnect the battery before performing service on
the generator.
■ Always be sure the operator is familiar with proper safety
precautionsandoperationstechniques beforeusinggenerator.
■ 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.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in Operator’s
Manual before attempting to operate equipment.
■ Always be sure the operator is familiar with proper safety
precautionsandoperationstechniques beforeusinggenerator.
■ Refer to the Komatsu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
■ Beforelifting,makesure thegenerator'sliftinghookissecure
andthat thereis noapparent damageto the generatoritself
(loosescrews,nutsandbolts).Ifanypartislooseordamaged,
pleasetake correctiveaction beforelifting.
■ Alwaysdrain fuel priorto lifting.
■ Alwaysmake sure craneor liftingdevice has beenproperly
securedto thehook of guardframeon generator.
■ NEVER lift the machine while the engine is running.
■ Useadequateliftingcable(wireorrope)ofsufficientstrength.
■ Whenlifting thegenerator, alwaysuse thebalanced center-
point suspensionhook and liftstraight upwards.
■ NEVERallowany personor animaltostand underneaththe
machinewhile lifting.
■ When loading the generator on a truck, be sure to use the
frontandbackframebarsasameanstosecurethegenerator
duringtransport.
Battery
Never over fill the battery with water above
theupper limit.
CAUTION:
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Usewellinsulated gloveswhenpickingup thebattery.Use the
following guidelines when handling the battery:
RULES FOR SAFE OPERATION
1. DO NOT drop the battery.There is the possibility of risk
that the battery may explode.
2. 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.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Alwayskeep batterychargingandboostercables ingood
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
toavoidriskofadangerousconcentrationofcombustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plentyofwater,thencontactthenearestdoctororhospital,
and seek medical attention.

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 9
Transporting
■ Alwaysshutdown enginebefore transporting.
■ Tightenfuel tankcap securely.
■ Drainfuel when transportinggenerator over longdistances
orbad roads.
■ Always tie-down the generator during transportation by
securing thegenerator.
■ Ifgeneratorismountedonatrailer,makesuretrailercomplies
withall localand state safetytransportation laws.See page
10for basictowing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit . Knowthelocationofthe nearesttelephone.
Also know the phone numbers of the nearest
ambulance ,
doctor and fire department .
RULES FOR SAFE OPERATION
Maintenance Safety
■ NEVERlubricatecomponentsorattemptserviceonarunning
machine.
■ Always allow the machine a proper amount of time to cool
beforeservicing.
■ Keepthe machinery inproper running condition.
■ Fixdamageto themachineimmediately andalwaysreplace
brokenparts.
■ Disposeofhazardouswasteproperly.Examplesofpotentially
hazardouswaste areused motor oil,fuel, andfuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source

PAGE 10 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure1) that supports thegeneratorand thetowingvehicle
are in good operating condition and both units are
mechanically sound.
Thefollowing listofsuggestionsshouldbe usedwhentowing
yourgenerator:
CAUTION :
Towing Safety Precautions
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup,brake, andtrailerlights areconnected and working
properly.
■ Rememberthemaximumspeedunless otherwisepostedfor
highwaytowing is 45 MPH.Recommended off-road towing
isnottoexceed10 MPH orlessdependingon typeofterrain.
■ Place chockedblocks underneathwheel toprevent rolling,
whileparked.
■ Place support blocks underneath the trailer's bumper to
prevent
tipping , whileparked.
■ Usethetrailer'shand winchtoadjust theheight ofthetrailer,
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
gasmilage.
■ Avoidsharp turnsto prevent rolling.
■ Removewheel standwhen transporting.
■ DO NOT transportgenerator with fuelin tank.
Check with your county or state safety
towing regulations department before
towingyourgenerator.
■ Make sure the hitch and coupling of the towing vehicle are
ratedequalto,orgreaterthanthetrailer"grossvehicleweight
rating"(GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
towa trailerwith defectivehitches, couplings,chainsetc.
■ Check the tire air pressure on both the towing vehicle and
thetrailer.Alsocheck thetire tread wearonboth vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
DCA-800SSK —TOWING
Figure 1. TypicalTrailer Description