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Multiquip DCA-300SSK manual Models, Operation And Parts Manual, Whisperwatttm Series

Models: DCA-300SSK

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OPERATION AND PARTS MANUAL

WHISPERWATTTM SERIES

MODELS:

DCA-300SSK

DCA-300SSK2

DCA-300SSK3

60 Hz GENERATORS

PARTS LIST NO. C2871300704

SERIAL NO. 3708297~

Revision #4 (03/27/06)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES.

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Multiquip DCA-300SSK manual Models, Operation And Parts Manual, Whisperwatttm Series, Revision #4 03/27/06

Contents

OPERATION AND PARTS MANUAL MODELSPARTS LIST NO. C2871300704 SERIAL NO. 3708297~ WHISPERWATTTM SERIESPage WARRANTYDEPARTMENT SERVICE DEPARTMENTPARTS DEPARTMENT TECHNICAL ASSISTANCESpecification and part TABLE OF CONTENTSNOTEnumber are subject to change without notice MQPower DCA-300SSK SERIES AC GeneratorHere’s how to get help PARTS ORDERING PROCEDURESDirect TOLL-FREE access to our Parts Department When ordering parts please supply the following informationTable 1. Generator Specifications DCA-300SSK SERIES - SPECIFICATIONSTable 2. Engine Specifications 1800Figure 1. Dimensions DCA-300SSK SERIES - DIMENSIONS TOP, SIDE AND FRONTTABLE 3. DIMENSIONS Dimension in. mmHAZARD SYMBOLS DCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS Whisperwatt GeneratorWARNING - ROTATING PARTS DCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDCA-300SSK SERIES - RULES FOR SAFE OPERATION General SafetyDANGER - READTHIS MANUAL DCA-300SSK SERIES - RULES FOR SAFE OPERATION Electrical SafetyGenerator Grounding DANGER - ELECTROCUTION HAZARDSBattery Safety Maintenance SafetyDCA-400SSVU - RULES FOR SAFE OPERATION DANGER - EXPLOSION HAZARDSDCA-400SSVU - RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies Figure 2. Generator Decals DCA-300SSK SERIES - GENERATOR DECALSFigure 3. Generator Decals DCA-300SSK SERIES - GENERATOR DECALSFigure 4. Typical Generator Grounding Application DCA-300SSK SERIES - INSTALLATIONOutdoor Installation DCA-300SSK SERIES - INSTALLATIONIndoor Installation CAUTION - EXHAUST HAZARDDCA-300SSK FAMILIARIZATION Generator DCA-300SSK SERIES - GENERAL INFORMATIONEngine Control Panel Generator Control PanelTable 4. Generator Major Components DCA-300SSK SERIES - MAJOR COMPONENTSFigure 5. Major Components ITEM NOS/N 3701673 and Below S/N 3701674 and Above DCA-300SSK - GENERATOR CONTROL PANELFigure 6. Generator Control Panel DCA-300SSK - GENERATOR CONTROL PANEL S/N 3701673 and Below S/N 3701674 and Above DCA-300SSK - ENGINE OPERATING PANELFigure 7. Engine Operating Panels DCA-300SSK - ENGINE OPERATING PANEL Output Terminal Familiarization DCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATIONThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal PanelDCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATION 120VAC GFCI ReceptaclesFigure 11. Voltage Regulator Control Knob Figure 9. G.F.C.I. ReceptacleMaximum Power Output KW Connecting LoadsOver Current Relay Figure 12. Connecting LoadsThree Phase Load Single Phase LoadDCA-300SSK SERIES - LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSTable 9. Generator Ampere Ratings ⎯ 3∅ DCA-300SSK SERIES - GENERATOR OUTPUTSTable 7. Generator Available Voltages Generator OutputVoltagesDCA-300SSK SERIES - GENERATOR OUTPUTS/GAUGE READING How to Read the Output Terminal GaugeMaximum Amps Table 10. Generator Maximum AmpsUVWO Terminal Output Voltages DCA-300SSK SERIES - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages1Ø-480V UVWO Terminal Output Voltages 3Ø-480V UVWO Terminal Output Voltages1Ø-277V UVWO Terminal Output Voltages Figure 25. Voltage Change-Over Board 480V ConfigurationTable 11. Recommended Motor Oil DCA-300SSK SERIES - PRE-SETUPCircuit Breakers Lubrication OilRefueling Procedure DCA-300SSK SERIES - PRE-SETUPCAUTION - REFUELINGTRAILER FUELTANK WARNING - RESPIRATORY HAZARDSDO NOT wait for fuel to rise in filler neck. See Figure DCA-300SSK SERIES - PRE-SETUPCleaning the Radiator DCA-300SSK SERIES - PRE-SETUPAir Cleaner must be less than 50%Battery Cable Installation BatteryCAUTION - BATTERY SERVICING SAFETY Wiringhandle DCA-300SSK SERIES - GEN. START-UP PROCEDURE MANUALCAUTION - LETHAL EXHAUST HAZARD WARNING - STARTINGTHE GENERATOR6. Set the battery ON/OFF switch Figure 43 to the “ON” position DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL9. Place the engine throttle control in the “LOW” position Figure Figure 53. Coolant Temperature Gauge DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUALFigure 52. Oil Pressure Gauge Figure 55. Main, Aux. and GFCI Circuit Breakers ONDCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL Operating Panel S/N 3701673 and belowFigure 60. Engine Speed Switch Low Figure 61. Auto-Off/Reset-Manual SwitchCAUTION - BACKUP GENERATOR USE DCA-300SSK SERIES - GEN. START-UP PROCEDURE AUTO MODE2. Set the battery ON/OFF switch Figure 64 to the “ON” position WARNING - AUTO MODE MAINTENANCEEmergency Shutdown Procedure DCA-300SSK SERIES - GEN. SHUT-DOWN PROCEDURE MANUALEngine Shutdown Controller S/N 3701674~ WARNING - SHUTTING DOWNTHE GENERATORNOTE PAGE TABLE 13. INSPECTION / MAINTENANCE DCA-300SSK SERIES - MAINTENANCE10 Hrs 250 HrsService Daily DCA-300SSK SERIES - MAINTENANCECleaning the Fuel Strainer General InspectionChanging Oil Flushing Out Radiator and Changing CoolantReplacing Fuel Filter DCA-300SSK SERIES - MAINTENANCEGreasing Cleaning Breather ElementGenerator Storage Removal From Long Term StorageNOTEapplied to the generators internal battery charger DCA-300SSK SERIES - MAINTENANCETrailer Maintenance DCA-300SSK SERIES -TRAILER MAINTENANCEBrakes Brake AdjustmentHydraulic Surge Brakes ActuatorCAUTION - EYESIGHT HAZARD Tires/Wheels/Lug NutsSuspension Tire Wear/InflationLug Nut Torque Requirements DCA-300SSK SERIES -TRAILER MAINTENANCEFigure 76. Wheel Lug Nuts Tightening Sequence Table 17. Tire Torque RequirementsFigure 77. Trailer/Towing Vehicle Wiring Diagram DCA-300SSK -TRAILER-WIRING DIAGRAMFigure 78. Generator Wiring Diagram DCA-300SSK - GENERATORWIRING DIAGRAMFigure 79. Engine Wiring Diagram S/N 3696506 and Below DCA-300SSK- ENGINEWIRING DIAGRAM S/N 3696506 AND BELOWFigure 80. Engine Wiring Diagram S/N DCA-300SSK - ENGINE WIRING DIAGRAM S/N3696507TOFigure 81. Engine Wiring Diagram S/N 3701674 and Above DCA-300SSK - ENGINE WIRING DIAGRAM S/N 3701674 AND ABOVETABLE 18. ENGINE TROUBLESHOOTING DCA-300SSK -TROUBLESHOOTING ENGINEEngine does not start Starter does not runTABLE 18. ENGINE TROUBLESHOOTING CONTINUED DCA-300SSK -TROUBLESHOOTING ENGINEEngine revolution is not smoothTABLE 19. GENERATOR TROUBLESHOOTING DCA-300SSK -TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMTABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-300SSK -TROUBLESHOOTING ENGNE CONTROLLERSolution SymptonNO. Column EXPLANATION OF CODE IN REMARKS COLUMNPART NO. Column QTY. Column1 to 5 Units DCA-300SSK - SUGGESTED SPARE PARTSDescription DCA-300SSKW/KOMATSU SA6D125E-2/ SAA6D125E-2GENERATOR ASSY DCA-300SSK GENERATOR ASSYREMARKS PART NAMEDCA-300SSK GENERATOR ASSY DCA-300SSK GENERATOR ASSY PART NAME DCA-300SSK GENERATOR ASSYREMARKS S/N3691259 TOCONTROL BOX ASSY DCA-300SSK CONTROL BOX ASSYPART NAME DCA-300SSK CONTROL BOX ASSYREMARKS C2214000102CONTROL BOX ASSY. CONT DCA-300SSK CONTROL BOX ASSYPART NAME DCA-300SSK CONTROL BOX ASSYREMARKS RA20A2SE102BJ 2W 1K OHMDCA-300SSK CONTROL BOX ASSY PART NAME DCA-300SSK CONTROL BOX ASSYREMARKS ECU9988N300/400ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOWPART NAME DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOWREMARKS REPLACES C2924200014ENGINE & RADIATOR ASSY. UP TO S/N3697258 DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258PART NAME DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258ENGINE & RADIATOR ASSY. S/N3691259 TO S/N DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TODCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TO ELEMENT, AIR CLEANER, INNER/OUTERPART NAME REMARKSENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVEPART NAME DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVEREMARKS DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE PART NAME DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVEENGINE OPERATING PANEL ASSY DCA-300SSK ENGINE OPERATING PANEL ASSYS/N3701674~ UP TO S/N3701673 PART NAME DCA-300SSK ENGINE OPERATING PANEL ASSYREMARKS OUTPUT TERMINAL ASSY DCA-300SSK OUTPUTTERMINAL ASSYUP TO S/N3691258 S/N3691259~ PART NAME DCA-300SSK OUTPUTTERMINAL ASSYREMARKS UP TO S/N3691258 S/N3691259~ DCA-300SSK OUTPUTTERMINAL ASSYPART NAME DCA-300SSK OUTPUTTERMINAL ASSYREMARKS ACTUATOR ASSY. S/N3701674~ DCA-300 SSK ACTUATOR ASSYPART NAME DCA-300 SSK ACTUATOR ASSYREMARKS ACTUATORBATTERY ASSY DCA-300 SSK BATTERY ASSYPART NAME DCA-300 SSK BATTERY ASSYMUFFLER ASSY DCA-300SSK MUFFLER ASSYPART NAME DCA-300SSK MUFFLER ASSYREMARKS FUEL TANK ASSY DCA-300SSK FUELTANK ASSYPART NAME DCA-300SSK FUELTANK ASSYREMARKS THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-300SSK ENCLOSURE ASSY. UP TO S/NOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. UPTO S/NREMARKS DCA-300SSK ENCLOSURE ASSY. UP TO S/N THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. UPTO S/NREMARKS DCA-300SSK ENCLOSURE ASSY. UP TO S/N THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. UPTO S/NREMARKS THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-300SSK ENCLOSURE ASSY. S/N 3708297~OF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. S/N 3708297~DCA-300SSK ENCLOSURE ASSY. S/N 3708297~ THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. S/N 3708297~DCA-300SSK ENCLOSURE ASSY. S/N 3708297~ THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-300SSK ENCLOSURE ASSY. S/N 3708297~RUBBER SEAL ASSY DCA-300SSK RUBBER SEAL ASSYREMARKS DCA-300SSK RUBBER SEAL ASSYPART NAME S/N3701674 AND ABOVEOIL PIPING ASSY DCA-300SSK OIL PIPING ASSYPART NAME DCA-300SSK OIL PIPING ASSYNAMEPLATE AND DECALS DCA-300SSK NAMEPLATE AND DECALSDCA-300SSK NAMEPLATE AND DECALS DECAL 3-PHASE OUTPUT TERMINALPART NAME REMARKSDCA-300SSK NAMEPLATE AND DECALS PART NAME DCA-300SSK NAME PLATE AND DECALSREMARKS DCA-300SSK NAMEPLATE AND DECALS PART NAME DCA-300SSK NAMEPLATE AND DECALSREMARKS Effective October 1 TERMS AND CONDITIONS OF SALE - PARTS11. Credit issued will be applied to future purchasesonly SPECIAL EXPEDITING SERVICENOTE PAGE SERVICE DEPARTMENT HERES HOW TO GET HELPPARTS DEPARTMENT TECHNICAL ASSISTANCE