Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip manual DCA-300SSK CONTROL BOX ASSY, Control Box Assy

Models: DCA-300SSK

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DCA-300SSK CONTROL BOX ASSY.

DCA-300SSK CONTROL BOX ASSY.

CONTROL BOX ASSY.

PAGE 68 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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Multiquip manual DCA-300SSK CONTROL BOX ASSY, Control Box Assy

Contents

MODELS OPERATION AND PARTS MANUALPARTS LIST NO. C2871300704 SERIAL NO. 3708297~ WHISPERWATTTM SERIESPage SERVICE DEPARTMENT WARRANTYDEPARTMENTPARTS DEPARTMENT TECHNICAL ASSISTANCETABLE OF CONTENTS Specification and partNOTEnumber are subject to change without notice MQPower DCA-300SSK SERIES AC GeneratorPARTS ORDERING PROCEDURES Here’s how to get helpDirect TOLL-FREE access to our Parts Department When ordering parts please supply the following informationDCA-300SSK SERIES - SPECIFICATIONS Table 1. Generator SpecificationsTable 2. Engine Specifications 1800DCA-300SSK SERIES - DIMENSIONS TOP, SIDE AND FRONT Figure 1. DimensionsTABLE 3. DIMENSIONS Dimension in. mmDCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSSAFETY MESSAGE ALERT SYMBOLS Whisperwatt GeneratorDCA-300SSK SERIES - SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDANGER - READTHIS MANUAL General SafetyDCA-300SSK SERIES - RULES FOR SAFE OPERATION Electrical Safety DCA-300SSK SERIES - RULES FOR SAFE OPERATIONGenerator Grounding DANGER - ELECTROCUTION HAZARDSMaintenance Safety Battery SafetyDCA-400SSVU - RULES FOR SAFE OPERATION DANGER - EXPLOSION HAZARDSEmergencies Towing & Transporting SafetyDCA-400SSVU - RULES FOR SAFE OPERATION DCA-300SSK SERIES - GENERATOR DECALS Figure 2. Generator DecalsDCA-300SSK SERIES - GENERATOR DECALS Figure 3. Generator DecalsDCA-300SSK SERIES - INSTALLATION Figure 4. Typical Generator Grounding ApplicationDCA-300SSK SERIES - INSTALLATION Outdoor InstallationIndoor Installation CAUTION - EXHAUST HAZARDDCA-300SSK SERIES - GENERAL INFORMATION DCA-300SSK FAMILIARIZATION GeneratorEngine Control Panel Generator Control PanelDCA-300SSK SERIES - MAJOR COMPONENTS Table 4. Generator Major ComponentsFigure 5. Major Components ITEM NOFigure 6. Generator Control Panel DCA-300SSK - GENERATOR CONTROL PANELS/N 3701673 and Below S/N 3701674 and Above DCA-300SSK - GENERATOR CONTROL PANEL Figure 7. Engine Operating Panels DCA-300SSK - ENGINE OPERATING PANELS/N 3701673 and Below S/N 3701674 and Above DCA-300SSK - ENGINE OPERATING PANEL DCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal FamiliarizationThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal Panel120VAC GFCI Receptacles DCA-300SSK SERIES - OUTPUT TERMINAL PANEL FAMILIARIZATIONFigure 11. Voltage Regulator Control Knob Figure 9. G.F.C.I. ReceptacleConnecting Loads Maximum Power Output KWOver Current Relay Figure 12. Connecting LoadsSingle Phase Load Three Phase LoadDCA-300SSK SERIES - LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSDCA-300SSK SERIES - GENERATOR OUTPUTS Table 9. Generator Ampere Ratings ⎯ 3∅Table 7. Generator Available Voltages Generator OutputVoltagesHow to Read the Output Terminal Gauge DCA-300SSK SERIES - GENERATOR OUTPUTS/GAUGE READINGMaximum Amps Table 10. Generator Maximum AmpsDCA-300SSK SERIES - OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages3Ø-480V UVWO Terminal Output Voltages 1Ø-480V UVWO Terminal Output Voltages1Ø-277V UVWO Terminal Output Voltages Figure 25. Voltage Change-Over Board 480V ConfigurationDCA-300SSK SERIES - PRE-SETUP Table 11. Recommended Motor OilCircuit Breakers Lubrication OilDCA-300SSK SERIES - PRE-SETUP Refueling ProcedureCAUTION - REFUELINGTRAILER FUELTANK WARNING - RESPIRATORY HAZARDSDCA-300SSK SERIES - PRE-SETUP DO NOT wait for fuel to rise in filler neck. See FigureDCA-300SSK SERIES - PRE-SETUP Cleaning the RadiatorAir Cleaner must be less than 50%Battery Battery Cable InstallationCAUTION - BATTERY SERVICING SAFETY WiringDCA-300SSK SERIES - GEN. START-UP PROCEDURE MANUAL handleCAUTION - LETHAL EXHAUST HAZARD WARNING - STARTINGTHE GENERATOR9. Place the engine throttle control in the “LOW” position Figure DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL6. Set the battery ON/OFF switch Figure 43 to the “ON” position DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUAL Figure 53. Coolant Temperature GaugeFigure 52. Oil Pressure Gauge Figure 55. Main, Aux. and GFCI Circuit Breakers ONOperating Panel S/N 3701673 and below DCA-300SSK SERIES - GENERATOR START-UP PROCEDURE MANUALFigure 60. Engine Speed Switch Low Figure 61. Auto-Off/Reset-Manual SwitchDCA-300SSK SERIES - GEN. START-UP PROCEDURE AUTO MODE CAUTION - BACKUP GENERATOR USE2. Set the battery ON/OFF switch Figure 64 to the “ON” position WARNING - AUTO MODE MAINTENANCEDCA-300SSK SERIES - GEN. SHUT-DOWN PROCEDURE MANUAL Emergency Shutdown ProcedureEngine Shutdown Controller S/N 3701674~ WARNING - SHUTTING DOWNTHE GENERATORNOTE PAGE DCA-300SSK SERIES - MAINTENANCE TABLE 13. INSPECTION / MAINTENANCE10 Hrs 250 HrsDCA-300SSK SERIES - MAINTENANCE Service DailyCleaning the Fuel Strainer General InspectionFlushing Out Radiator and Changing Coolant Changing OilReplacing Fuel Filter DCA-300SSK SERIES - MAINTENANCECleaning Breather Element GreasingGenerator Storage Removal From Long Term StorageDCA-300SSK SERIES - MAINTENANCE NOTEapplied to the generators internal battery chargerDCA-300SSK SERIES -TRAILER MAINTENANCE Trailer MaintenanceBrake Adjustment BrakesHydraulic Surge Brakes ActuatorTires/Wheels/Lug Nuts CAUTION - EYESIGHT HAZARDSuspension Tire Wear/InflationDCA-300SSK SERIES -TRAILER MAINTENANCE Lug Nut Torque RequirementsFigure 76. Wheel Lug Nuts Tightening Sequence Table 17. Tire Torque RequirementsDCA-300SSK -TRAILER-WIRING DIAGRAM Figure 77. Trailer/Towing Vehicle Wiring DiagramDCA-300SSK - GENERATORWIRING DIAGRAM Figure 78. Generator Wiring DiagramDCA-300SSK- ENGINEWIRING DIAGRAM S/N 3696506 AND BELOW Figure 79. Engine Wiring Diagram S/N 3696506 and BelowDCA-300SSK - ENGINE WIRING DIAGRAM S/N3696507TO Figure 80. Engine Wiring Diagram S/NDCA-300SSK - ENGINE WIRING DIAGRAM S/N 3701674 AND ABOVE Figure 81. Engine Wiring Diagram S/N 3701674 and AboveDCA-300SSK -TROUBLESHOOTING ENGINE TABLE 18. ENGINE TROUBLESHOOTINGEngine does not start Starter does not runDCA-300SSK -TROUBLESHOOTING ENGINE TABLE 18. ENGINE TROUBLESHOOTING CONTINUEDEngine revolution is not smoothDCA-300SSK -TROUBLESHOOTING GENERATOR TABLE 19. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-300SSK -TROUBLESHOOTING ENGNE CONTROLLER TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPECSolution SymptonEXPLANATION OF CODE IN REMARKS COLUMN NO. ColumnPART NO. Column QTY. ColumnDCA-300SSK - SUGGESTED SPARE PARTS 1 to 5 UnitsDescription DCA-300SSKW/KOMATSU SA6D125E-2/ SAA6D125E-2DCA-300SSK GENERATOR ASSY GENERATOR ASSYDCA-300SSK GENERATOR ASSY PART NAMEREMARKS DCA-300SSK GENERATOR ASSY DCA-300SSK GENERATOR ASSY PART NAMEREMARKS S/N3691259 TODCA-300SSK CONTROL BOX ASSY CONTROL BOX ASSYDCA-300SSK CONTROL BOX ASSY PART NAMEREMARKS C2214000102DCA-300SSK CONTROL BOX ASSY CONTROL BOX ASSY. CONTDCA-300SSK CONTROL BOX ASSY PART NAMEREMARKS RA20A2SE102BJ 2W 1K OHMDCA-300SSK CONTROL BOX ASSY DCA-300SSK CONTROL BOX ASSY PART NAMEREMARKS ECU9988N300/400DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOWDCA-300SSK ENGINE & RADIATOR ASSY. S/N 3697258 AND BELOW PART NAMEREMARKS REPLACES C2924200014DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258 ENGINE & RADIATOR ASSY. UP TO S/N3697258DCA-300SSK ENGINE & RADIATOR ASSY. UPTO S/N3697258 PART NAMEDCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TO ENGINE & RADIATOR ASSY. S/N3691259 TO S/NELEMENT, AIR CLEANER, INNER/OUTER DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270TOPART NAME REMARKSDCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVEREMARKS DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVEPART NAME DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE DCA-300SSK ENGINE & RADIATOR ASSY. S/N 3708270 AND ABOVE PART NAMES/N3701674~ UP TO S/N3701673 DCA-300SSK ENGINE OPERATING PANEL ASSYENGINE OPERATING PANEL ASSY REMARKS DCA-300SSK ENGINE OPERATING PANEL ASSYPART NAME UP TO S/N3691258 S/N3691259~ DCA-300SSK OUTPUTTERMINAL ASSYOUTPUT TERMINAL ASSY REMARKS DCA-300SSK OUTPUTTERMINAL ASSYPART NAME DCA-300SSK OUTPUTTERMINAL ASSY UP TO S/N3691258 S/N3691259~REMARKS DCA-300SSK OUTPUTTERMINAL ASSYPART NAME DCA-300 SSK ACTUATOR ASSY ACTUATOR ASSY. S/N3701674~DCA-300 SSK ACTUATOR ASSY PART NAMEREMARKS ACTUATORDCA-300 SSK BATTERY ASSY BATTERY ASSYDCA-300 SSK BATTERY ASSY PART NAMEDCA-300SSK MUFFLER ASSY MUFFLER ASSYREMARKS DCA-300SSK MUFFLER ASSYPART NAME DCA-300SSK FUELTANK ASSY FUEL TANK ASSYREMARKS DCA-300SSK FUELTANK ASSYPART NAME 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-GRAYREMARKS DCA-300SSK ENCLOSURE ASSY. UPTO S/NPART NAME 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-GRAYREMARKS DCA-300SSK ENCLOSURE ASSY. UPTO S/NPART NAME 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-GRAYREMARKS DCA-300SSK ENCLOSURE ASSY. UPTO S/NPART NAME 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-GRAYDCA-300SSK ENCLOSURE ASSY. S/N 3708297~ PART NAMETHE 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-GRAYDCA-300SSK ENCLOSURE ASSY. S/N 3708297~ PART NAMETHE 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-GRAYDCA-300SSK ENCLOSURE ASSY. S/N 3708297~ PART NAMEDCA-300SSK RUBBER SEAL ASSY RUBBER SEAL ASSYDCA-300SSK RUBBER SEAL ASSY REMARKSPART NAME S/N3701674 AND ABOVEDCA-300SSK OIL PIPING ASSY OIL PIPING ASSYDCA-300SSK OIL PIPING ASSY PART NAMEDCA-300SSK NAMEPLATE AND DECALS NAMEPLATE AND DECALSDECAL 3-PHASE OUTPUT TERMINAL DCA-300SSK NAMEPLATE AND DECALSPART NAME REMARKSDCA-300SSK NAMEPLATE AND DECALS REMARKS DCA-300SSK NAME PLATE AND DECALSPART NAME DCA-300SSK NAMEPLATE AND DECALS REMARKS DCA-300SSK NAMEPLATE AND DECALSPART NAME TERMS AND CONDITIONS OF SALE - PARTS Effective October 111. Credit issued will be applied to future purchasesonly SPECIAL EXPEDITING SERVICENOTE PAGE HERES HOW TO GET HELP SERVICE DEPARTMENTPARTS DEPARTMENT TECHNICAL ASSISTANCE