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manual DCA-300SSK SERIES - INSTALLATION, Typical Generator Grounding Application
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DCA-300SSK
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Troubleshooting
Specs
Install
Parts list
DCA-300SSK -TRAILER-WIRING DIAGRAM
Warranty
Dimension
Maintenance
240V Configuration
Connecting Loads
Page 16
Image 16
DCA-300SSK
SERIES — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 16 —
DCA-300SSK
SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
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Page 17
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Image 16
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Contents
MODELS
OPERATION AND PARTS MANUAL
PARTS LIST NO. C2871300704 SERIAL NO. 3708297~
WHISPERWATTTM SERIES
Page
SERVICE DEPARTMENT
WARRANTYDEPARTMENT
PARTS DEPARTMENT
TECHNICAL ASSISTANCE
TABLE OF CONTENTS
Specification and part
NOTEnumber are subject to change without notice
MQPower DCA-300SSK SERIES AC Generator
PARTS ORDERING PROCEDURES
Here’s how to get help
Direct TOLL-FREE access to our Parts Department
When ordering parts please supply the following information
DCA-300SSK SERIES - SPECIFICATIONS
Table 1. Generator Specifications
Table 2. Engine Specifications
1800
DCA-300SSK SERIES - DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
TABLE 3. DIMENSIONS
Dimension in. mm
DCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
Whisperwatt Generator
DCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEED CONDITIONS
DCA-300SSK SERIES - RULES FOR SAFE OPERATION
General Safety
DANGER - READTHIS MANUAL
Electrical Safety
DCA-300SSK SERIES - RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
Maintenance Safety
Battery Safety
DCA-400SSVU - RULES FOR SAFE OPERATION
DANGER - EXPLOSION HAZARDS
DCA-400SSVU - RULES FOR SAFE OPERATION
Towing & Transporting Safety
Emergencies
DCA-300SSK SERIES - GENERATOR DECALS
Figure 2. Generator Decals
DCA-300SSK SERIES - GENERATOR DECALS
Figure 3. Generator Decals
DCA-300SSK SERIES - INSTALLATION
Figure 4. Typical Generator Grounding Application
DCA-300SSK SERIES - INSTALLATION
Outdoor Installation
Indoor Installation
CAUTION - EXHAUST HAZARD
DCA-300SSK SERIES - GENERAL INFORMATION
DCA-300SSK FAMILIARIZATION Generator
Engine Control Panel
Generator Control Panel
DCA-300SSK SERIES - MAJOR COMPONENTS
Table 4. Generator Major Components
Figure 5. Major Components
ITEM NO
S/N 3701673 and Below S/N 3701674 and Above
DCA-300SSK - GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
DCA-300SSK - GENERATOR CONTROL PANEL
S/N 3701673 and Below S/N 3701674 and Above
DCA-300SSK - ENGINE OPERATING PANEL
Figure 7. Engine Operating Panels
DCA-300SSK - ENGINE OPERATING PANEL
DCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
The “Output Terminal Panel ” Figure 8 is provided with the following
Output Terminal Panel
120VAC GFCI Receptacles
DCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 11. Voltage Regulator Control Knob
Figure 9. G.F.C.I. Receptacle
Connecting Loads
Maximum Power Output KW
Over Current Relay
Figure 12. Connecting Loads
Single Phase Load
Three Phase Load
DCA-300SSK SERIES - LOAD APPLICATION
DANGER - ELECTRICAL SYSTEM HAZARDS
DCA-300SSK SERIES - GENERATOR OUTPUTS
Table 9. Generator Ampere Ratings ⎯ 3∅
Table 7. Generator Available Voltages
Generator OutputVoltages
How to Read the Output Terminal Gauge
DCA-300SSK SERIES - GENERATOR OUTPUTS/GAUGE READING
Maximum Amps
Table 10. Generator Maximum Amps
DCA-300SSK SERIES - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240V UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
3Ø-480V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
Figure 25. Voltage Change-Over Board 480V Configuration
DCA-300SSK SERIES - PRE-SETUP
Table 11. Recommended Motor Oil
Circuit Breakers
Lubrication Oil
DCA-300SSK SERIES - PRE-SETUP
Refueling Procedure
CAUTION - REFUELINGTRAILER FUELTANK
WARNING - RESPIRATORY HAZARDS
DCA-300SSK SERIES - PRE-SETUP
DO NOT wait for fuel to rise in filler neck. See Figure
DCA-300SSK SERIES - PRE-SETUP
Cleaning the Radiator
Air Cleaner
must be less than 50%
Battery
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
Wiring
DCA-300SSK SERIES - GEN. START-UP PROCEDURE MANUAL
handle
CAUTION - LETHAL EXHAUST HAZARD
WARNING - STARTINGTHE GENERATOR
6. Set the battery ON/OFF switch Figure 43 to the “ON” position
DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL
9. Place the engine throttle control in the “LOW” position Figure
DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL
Figure 53. Coolant Temperature Gauge
Figure 52. Oil Pressure Gauge
Figure 55. Main, Aux. and GFCI Circuit Breakers ON
Operating Panel S/N 3701673 and below
DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL
Figure 60. Engine Speed Switch Low
Figure 61. Auto-Off/Reset-Manual Switch
DCA-300SSK SERIES - GEN. START-UP PROCEDURE AUTO MODE
CAUTION - BACKUP GENERATOR USE
2. Set the battery ON/OFF switch Figure 64 to the “ON” position
WARNING - AUTO MODE MAINTENANCE
DCA-300SSK SERIES - GEN. SHUT-DOWN PROCEDURE MANUAL
Emergency Shutdown Procedure
Engine Shutdown Controller S/N 3701674~
WARNING - SHUTTING DOWNTHE GENERATOR
NOTE PAGE
DCA-300SSK SERIES - MAINTENANCE
TABLE 13. INSPECTION / MAINTENANCE
10 Hrs
250 Hrs
DCA-300SSK SERIES - MAINTENANCE
Service Daily
Cleaning the Fuel Strainer
General Inspection
Flushing Out Radiator and Changing Coolant
Changing Oil
Replacing Fuel Filter
DCA-300SSK SERIES - MAINTENANCE
Cleaning Breather Element
Greasing
Generator Storage
Removal From Long Term Storage
DCA-300SSK SERIES - MAINTENANCE
NOTEapplied to the generators internal battery charger
DCA-300SSK SERIES -TRAILER MAINTENANCE
Trailer Maintenance
Brake Adjustment
Brakes
Hydraulic Surge Brakes
Actuator
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
Suspension
Tire Wear/Inflation
DCA-300SSK SERIES -TRAILER MAINTENANCE
Lug Nut Torque Requirements
Figure 76. Wheel Lug Nuts Tightening Sequence
Table 17. Tire Torque Requirements
DCA-300SSK -TRAILER-WIRING DIAGRAM
Figure 77. Trailer/Towing Vehicle Wiring Diagram
DCA-300SSK - GENERATORWIRING DIAGRAM
Figure 78. Generator Wiring Diagram
DCA-300SSK- ENGINEWIRING DIAGRAM S/N 3696506 AND BELOW
Figure 79. Engine Wiring Diagram S/N 3696506 and Below
DCA-300SSK - ENGINE WIRING DIAGRAM S/N3696507TO
Figure 80. Engine Wiring Diagram S/N
DCA-300SSK - ENGINE WIRING DIAGRAM S/N 3701674 AND ABOVE
Figure 81. Engine Wiring Diagram S/N 3701674 and Above
DCA-300SSK -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING
Engine does not start
Starter does not run
DCA-300SSK -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING CONTINUED
Engine revolution is not
smooth
DCA-300SSK -TROUBLESHOOTING GENERATOR
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
DCA-300SSK -TROUBLESHOOTING ENGNE CONTROLLER
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Solution
Sympton
EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
PART NO. Column
QTY. Column
DCA-300SSK - SUGGESTED SPARE PARTS
1 to 5 Units
Description
DCA-300SSKW/KOMATSU SA6D125E-2/ SAA6D125E-2
DCA-300SSK GENERATOR ASSY
GENERATOR ASSY
REMARKS
PART NAME
DCA-300SSK GENERATOR ASSY
DCA-300SSK GENERATOR ASSY
DCA-300SSK GENERATOR ASSY
PART NAME
REMARKS
S/N3691259 TO
DCA-300SSK CONTROL BOX ASSY
CONTROL BOX ASSY
DCA-300SSK CONTROL BOX ASSY
PART NAME
REMARKS
C2214000102
DCA-300SSK CONTROL BOX ASSY
CONTROL BOX ASSY. CONT
DCA-300SSK CONTROL BOX ASSY
PART NAME
REMARKS
RA20A2SE102BJ 2W 1K OHM
DCA-300SSK CONTROL BOX ASSY
DCA-300SSK CONTROL BOX ASSY
PART NAME
REMARKS
ECU9988N300/400
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW
ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW
PART NAME
REMARKS
REPLACES C2924200014
DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258
ENGINE & RADIATOR ASSY. UP TO S/N3697258
DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258
PART NAME
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TO
ENGINE & RADIATOR ASSY. S/N3691259 TO S/N
ELEMENT, AIR CLEANER, INNER/OUTER
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TO
PART NAME
REMARKS
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE
ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE
PART NAME
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE
REMARKS
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE
DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE
PART NAME
ENGINE OPERATING PANEL ASSY
DCA-300SSK ENGINE OPERATING PANEL ASSY
S/N3701674~ UP TO S/N3701673
PART NAME
DCA-300SSK ENGINE OPERATING PANEL ASSY
REMARKS
OUTPUT TERMINAL ASSY
DCA-300SSK OUTPUTTERMINAL ASSY
UP TO S/N3691258 S/N3691259~
PART NAME
DCA-300SSK OUTPUTTERMINAL ASSY
REMARKS
DCA-300SSK OUTPUTTERMINAL ASSY
UP TO S/N3691258 S/N3691259~
PART NAME
DCA-300SSK OUTPUTTERMINAL ASSY
REMARKS
DCA-300 SSK ACTUATOR ASSY
ACTUATOR ASSY. S/N3701674~
DCA-300 SSK ACTUATOR ASSY
PART NAME
REMARKS
ACTUATOR
DCA-300 SSK BATTERY ASSY
BATTERY ASSY
DCA-300 SSK BATTERY ASSY
PART NAME
DCA-300SSK MUFFLER ASSY
MUFFLER ASSY
PART NAME
DCA-300SSK MUFFLER ASSY
REMARKS
DCA-300SSK FUELTANK ASSY
FUEL TANK ASSY
PART NAME
DCA-300SSK FUELTANK ASSY
REMARKS
DCA-300SSK ENCLOSURE ASSY. UP TO S/N
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
PART NAME
DCA-300SSK ENCLOSURE ASSY. UPTO S/N
REMARKS
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-300SSK ENCLOSURE ASSY. UP TO S/N
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
PART NAME
DCA-300SSK ENCLOSURE ASSY. UPTO S/N
REMARKS
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-300SSK ENCLOSURE ASSY. UP TO S/N
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
PART NAME
DCA-300SSK ENCLOSURE ASSY. UPTO S/N
REMARKS
DCA-300SSK ENCLOSURE ASSY. S/N 3708297~
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
DCA-300SSK ENCLOSURE ASSY. S/N 3708297~
PART NAME
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-GRAY
DCA-300SSK ENCLOSURE ASSY. S/N 3708297~
PART NAME
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-GRAY
DCA-300SSK ENCLOSURE ASSY. S/N 3708297~
PART NAME
DCA-300SSK RUBBER SEAL ASSY
RUBBER SEAL ASSY
DCA-300SSK RUBBER SEAL ASSY
REMARKS
PART NAME
S/N3701674 AND ABOVE
DCA-300SSK OIL PIPING ASSY
OIL PIPING ASSY
DCA-300SSK OIL PIPING ASSY
PART NAME
DCA-300SSK NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
DECAL 3-PHASE OUTPUT TERMINAL
DCA-300SSK NAMEPLATE AND DECALS
PART NAME
REMARKS
DCA-300SSK NAMEPLATE AND DECALS
PART NAME
DCA-300SSK NAME PLATE AND DECALS
REMARKS
DCA-300SSK NAMEPLATE AND DECALS
PART NAME
DCA-300SSK NAMEPLATE AND DECALS
REMARKS
TERMS AND CONDITIONS OF SALE - PARTS
Effective October 1
11. Credit issued will be applied to future purchasesonly
SPECIAL EXPEDITING SERVICE
NOTE PAGE
HERES HOW TO GET HELP
SERVICE DEPARTMENT
PARTS DEPARTMENT
TECHNICAL ASSISTANCE