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OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA800SSK2
60HZ GENERATOR (STD.)
(KOMATSU SAA6D170E-3 DIESEL ENGINE)
PARTS LIST NO. C5871301004
Revision # (09/03/09)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffi c Safety Administration (NHTSA) in addition to notifying Multiquip at 18004211244. If NHTSA receives similar complaints, it may open an investigation, and if it fi nds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in indivi
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TABLE OF CONTENTS DCA800SSK2 Component Drawings Generator Assembly ......................................... 56-59 60 Hz Generator Control Panel Assembly ................................... 60-61 Proposition 65 Warning ........................................... 2 Control Box Assembly ...................................... 62-65 Reporting Safety Defects ......................................... 3 Engine Assembly ............................................. 66-69 Table Of Contents .............
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PARTS ORDERING PROCEDURES Ordering parts has never been easier! Choose from three easy options: Effective: st January 1 , 2006 Best Deal! Order via Internet (Dealers Only): If you have an MQ Account, to obtain a Username Order parts on-line using Multiquip’s SmartEquip website! and Password, E-mail us at: parts@multiquip. com. View Parts Diagrams To obtain an MQ Account, contact your Order Parts District Sales Manager for more information. Print Specification Information Use the interne
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SAFETY INFORMATION Do not operate or service the equipment before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all equipment will be referenced with hazard symbols which times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages. could result in injury to yourself and others. SAFETY MESSAGES Th
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SAFETY INFORMATION NEVER use accessories or attachments that are not GENERAL SAFETY recommended by MQ Power for this equipment. Damage CAUTION to the equipment and/or injury to user may result. NEVER operate this equipment without proper protective ALWAYS know the location of the nearest clothing, shatterproof glasses, respiratory protection, fi re extinguisher. hearing protection, steel-toed boots and other protective ALWAYS know the location of the nearest devices required by the
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SAFETY INFORMATION ENGINE SAFETY NOTICE DANGER NEVER run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter The engine fuel exhaust gases contain poisonous carbon frequently to prevent engine malfunction. monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER tamper with the factory settings of the engine or engine governor. Damage The engine of this equipment to the engine or equipment can resu
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SAFETY INFORMATION Make sure the hitch and coupling of the towing vehicle FUEL SAFETY are rated equal to, or greater than the trailer “gross DANGER vehicle weight rating.” DO NOT start the engine near spilled fuel or combustible ALWAYS inspect the hitch and coupling for wear. NEVER fl uids. Diesel fuel is extremely fl ammable and its vapors tow a trailer with defective hitches, couplings, chains, etc. can cause an explosion if ignited. Check the tire air pressure on both towing vehi
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SAFETY INFORMATION Make sure power cables are securely connected to the ELECTRICAL SAFETY generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. DO NOT touch output terminals during operation. Contact with output terminals NOTICE during operation can cause electrocution, ALWAYS make certain that proper power or extension electrical shock or burn. cord has been selected for the job. See Cable Selection The electrical v
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SAFETY INFORMATION BATTERY SAFETY ENVIRONMENTAL SAFETY DANGER NOTICE DO NOT drop the battery. There is a possibility that the Dispose of hazardous waste properly. battery will explode. Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters. DO NOT expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains DO NOT use food or plastic containers to combustible gases and liquids. If these dispose of hazardous waste. gases and liquids com
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SPECIFICATIONS Table 1. Generator Specifi cations Model DCA800SSK2 (Standard) Revolving fi eld, self ventilated, Type open protected type synchronous generator Armature Connection Star with Neutral Phase 3 Standby Output 880 kVA (704 kW) Prime Output 800 kVA (640 kW) Voltage - 1 Ø 120, 127, 139, 240, 254, 277V Adjustable Voltage - 3 Ø 208, 220, 240, 416, 440, 480V Reconnectable Frequency 60 Hz Speed 1800 rpm Power Factor 0.8 Aux. AC Power Single Phase, 60 Hz Aux. Voltage/Output 4.8 Kw (2.4 kW x 2)
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DIMENSIONS Figure 1. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter A 43.31 in. (1,100 mm.) H 32.68 in. (830 mm.) B 36.22 in. (920 mm.) I 39.37 in. (1000 mm.) C 27.17 in. (690 mm.) J 29.53 in. (750 mm.) D 43.31 in. (1,100 mm.) K 240.54 in. (6110 mm.) E 29.53 in. (750 mm.) L 98.43 in. (2500 mm.) F 39.37 in. (1000 mm.) M 76.77 in. (1950 mm.) G 32.68 in. (830 mm.) DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) —
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INSTALLATION Figure 2. Typical Generator Grounding Application PAGE 14 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH generator is on secure level ground so that it cannot slide ground (Figure 2). or shift around. Also install the generator in a manner so Article 250 (Grounding) of the National Electrical Code that the exhaust will not b
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GENERAL INFORMATION GENERATOR OPEN DELTA EXCITATION SYSTEM The DCA800SSK2 generator is equipped with the state The MQ Power Model DCA800SSK2 is a 640 kW generator of the art “OpenDelta” excitation system. The open delta (Figure 3) that is designed as a high quality portable system consist of an electrically independent winding wound (requires a trailer for transport) power source for telecom among stationary windings of the AC output section. sites, lighting facilities, power tools, submer
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MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION 1 Air Filter Assembly 2 Muffl er Assembly 3 Fuel Tank Assembly 4 Engine Operating Panel Assembly 5 Battery Assembly 6 Output Terminal Panel Assembly 7 Generator Assembly 8 Generator Control Panel Assembly 9 Engine Control Panel Assembly Figure 3. Major Components DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 17
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GENERATOR CONTROL PANEL Figure 4. Generator Control Panel The defi nitions below describe the controls and functions of 9. Ammeter ChangeOver Switch — This switch allows the DCA800SSK2 Generator Control Panel (Figure 4). the AC ammeter to indicate the current fl owing to the load connected to any phase of the output terminals, or to be 1. AC Voltmeter — Indicates the output voltage present switched off. This switch does not effect the generator at the U,V, and W Output Terminal Lugs. output
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GENERATOR CONTROL PANEL 14. — Auto On/Off Engine Controller (MPEC) This Overcrank Shutdown — Indicates the unit has controller has a vertical row of status LED’s (inset), that attempted to start a pre programmed number of timesand when lit, indicate that an engine malfunction (fault) has has failed to start. The number of cycles and duration are been detected. When a fault has been detected the programmable. It is preset at 3 cycles with a 10second engine controller will evaluate the faul
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ENGINE OPERATING PANEL Figure 5. Engine Operating Panel 10. Fuel Gauge — Indicates amount of diesel fuel available. The defi nitions below describe the controls and functions 11. Engine Warning Lamps — There are six engine of the DCA800SSK2 Engine Operating Panel (Figure 5). warning lamps, they are defi ned as follows: 1. Battery Switch — This switch should be set to the ON a. Overheat Lamp — This lamp goes ON position during normal operation. When the engine has when the cooling water tempe
