reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with
permission.
This manual
remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the
specifications, design or the information published in this publication at any time without notice and without incurring any obligations.
MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should
DCA-300SSK SERIES WHISPERWATT AC Generators
. Multiquip Inc. reserves the right to discontinue or change
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 3
TABLE OF CONTENTS
MQPower DCA-300SSKMQPower DCA-300SSK
MQPower DCA-300SSK
MQPower DCA-300SSKMQPower DCA-300SSK
SERIES AC GeneratorSERIES AC Generator
SERIES AC Generator
SERIES AC GeneratorSERIES AC Generator
California Proposition 65 Warning ..................................... 2
Here's How To Get Help .................................................... 3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ...............................................5
Name Plate and Decals ......................................... 114-119
Terms and Condition of Sale — Parts .......................... 120
Specification and part
NOTE
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒❒
❒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:
❒❒
✓FedEx or UPS Ground
✓FedEx or UPS Second Day or Third Day
✓FedEx or UPS Next Day
✓Federal Express Priority One
✓DHL
✓Tr u c k
Note: Unless otherwise indicated by customer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours. We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Here’s how to get help...
Please have the model and serial number
on hand when calling.
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.800-421-1244
FAX:
Carson, CA 90746
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTY DEPARTMENT
800-835-2551,
310-537-3700,
EXT.
EXT.
279
279
310-632-2656
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
310-638-8046
FAX:
310-638-8046
FAX:
310-638-8046
Place Your Parts Order Via Web or Fax
For Even More Savings!
(Domestic USA Dealers Only)
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
OrderedStandardStock orders
viaorders($750 list and above)
Fax3%10%
Web5%10%
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
at no charge for freight
NOTE: DISCOUNTS ARE SUBJECT TO CHANGE
MQPOWER
A Division of Multiquip Inc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: 310-632-2656
E-MAIL: mqpower@multiquip.com
INTERNET: www.mqpower.com
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 5
PAGE 6 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
SNOISNEMID.3ELBAT
ecnerefeR
retteL
A).mm570,1(.ni23.24F ).mm570,1(.ni23.24
B).mm
C).mm046(.ni02.52H ).mm008,1(.ni89.07
D).mm585(.ni30.32I ).mm004,1(.ni21.55
E).m
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 7
).mm(.ninoisnemiDretteLecnerefeR).mm(.ninoisnemiD
510,1(.ni69.93G ).mm057,3(.ni46.741
m510,1(.ni69.93
DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.
This Owner's Manual has been
NOTE
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power
Model DCA-400SSVU
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
appear throughout this manual, and will be referenced in
conjunction with Safety "
WARNING - LETHAL EXHAUST GASES
Whisperwatt™ Generator.
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
Hazard Symbols
Message Alert Symbols
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH
if inhaled. NEVER operate this
Gasoline
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
is extremely flammable, and
" which
".
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
PAGE 8 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
WARNING - BURN HAZARDS
Engine components can generate extreme
heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of
electrical shock or burn,
severe bodily harm
electrocution,
which can cause
or even
DEATH!
DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep
hair
and clothing away from all moving
parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
fingers, hands
CAUTION - RESPIRATORY HAZARDS
,
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
ALWAYS wear approved
protection.
ALWAYS wear approved
hearing
protection.
respiratory
eye
and
This generator, other property,
NOTE
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 9
or the surrounding environment
could be damaged if you do not
follow instructions.
DCA-300SSK SERIES — RULES FOR SAFE OPERATION
■
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury
operated by trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the
General Safety:
■
DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
This equipment should not be operated by persons under
18 years of age.
■
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.
or even
DEATH
! This equipment is to be
DCA-400SSVU Whisperwatt™ AC Generator.
ALWAYS check the machine for loosened threads or bolts
before starting.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■
High Temperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot!
components can cause serious
burns.
■
The engine of this generator requires an adequate free
flow of cooling air.
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 generator or
engine and may cause injury
to people. The generator
engine gives off DEADLY
carbon monoxide gas.
bodily harm or even death.
NEVER
operate the generator in any
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the influence or
drugs or alcohol.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power 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. Unauthorized
equipment modification will void all warranties.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
NEVER run engine without air filter. Severe engine damage
may occur.
DO NOT leave the generator running in the
unattended.
Refer to the
technical questions or information.
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.
VOLVO Engine Owner's Manual
manual mode
for engine
PAGE 10 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of
electrical shock or burn,
Article 250 (Grounding) of the
National Electrical Code
severe bodily harm
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
The following safety recommendations should also be
followed:
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
terminals, insufficient tightening of the terminal connections
may cause damage to the generator
■
ALWAYS make sure generator is properly grounded.
■
NEVER use gas piping as an electrical ground.
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
DEATH!
per the
National Electrical Code
(NEC) and
injury
by electrocution can result from operating an
ungrounded generator.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
or
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
electrocution,
which can cause
or even
DEATH!
POWER
CORD
(POWER ON)
WET
HANDS
Electrical Safety
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the
National Electrical Code
(NEC) and local codes
before operating generator.
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 6.
■
NEVER power cables or cords
■
NEVER
stand in water
while AC power from the generator
lay in wate
r.
is being transfer to a load.
Backfeed to a utility system can
cause
electrocution
and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 11
DCA-400SSVU — RULES FOR SAFE OPERATION
Maintenance Safety
■
The electrical voltage required to operate the generator
can cause severe injury or even death through physical
contact with live circuits.
before performing maintenance on the generator.
■
NEVER lubricate components or attempt service on a
running machine.
■
ALWAYS disconnect the
before performing service on the generator.
■
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
■
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
Keep the machinery in proper running condition.
■
Fix damage to the machine immediately and always
replace broken parts.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
■
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
Turn all circuit breakers OFF
NEGATIVE battery terminal
Battery Safety
Use the following guidelines when handling the battery:
■
■
■■
■
■■
■■
■
■■
■■
■
■■
■■
■
■■
■■
■
■■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation,
glasses.
Use well insulated gloves when picking up the battery.
DANGER - EXPLOSION HAZARDS
The risk of an explosion exists when performing service
on the battery. To avoid
■■
■
DO NOT drop the battery. There
■■
is the possibility of risk that the
battery may explode.
■■
■
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.
ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
ALWAYS keep battery charging and cables in good
working condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
always
clothing or skin
EYES
wear safety
severe injury
, rinse eyes immediately with
or
DEATH:
, rinse skin or clothing
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
PAGE 12 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-400SSVU — RULES FOR SAFE OPERATION
■
Towing & Transporting Safety
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
The following list of safety precautions should be followed
when towing your generator:
CAUTION - FOLLOW TOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting
Transportation
towing your generator.
■
ALWAYS shutdown engine before transporting.
■
Tighten both fuel tank caps securely.
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed
guidelines for basic towing techniques.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating.”
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
(DOT)
Safety Towing Regulations
Towing & Transporting Safety
Department of
, before
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
while parked.
■
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
■
Avoid sharp turns.
■
Trailer should be adjusted to a level position at all times
when towing.
■
Raise and lock trailer wheel stand in up position when
transporting.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
prevent tipping, while parked.
■
Avoid sharp turns to prevent rolling.
■
DO NOT transport generator with fuel in tank.
Emergencies
chock blocks
support blocks
underneath wheel to prevent rolling,
underneath the trailer’s bumper to
■
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
z
z
Trailer tires should be inflated to 50 psi cold.
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 13
■
■
■
■
ALWAYS know the location of the
nearest
ALWAYS know the location of the
nearest and
ALWAYS know the location of the
nearest phone or
the job site,
ALWAYS have easy access to the phone
numbers of the nearest
and
be invaluable in the case of an emergency.
fire extinguisher
first aid kit
keep a phone on
in case of emergencies.
Fire Department
.
.
Ambulance, Doctor
. This information will
DCA-300SSK SERIES — GENERATOR DECALS
The DCA-300SSK generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for
operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
Figure 2. Generator Decals
PAGE 14 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — GENERATOR DECALS
Figure 3. Generator Decals
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 15
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)
DCA-300SSK SERIES — INSTALLATION
Outdoor Installation
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide or
shift around. Also install the generator in a manner so that
the exhaust will not be discharged in the direction of nearby
homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION - EXHAUST HAZARD
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
Indoor Installation
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1.Use one of the following wire types to connect the
generator to earth ground.
a.Copper - 10 AWG (5.3 mm2) or larger.
b.Aluminum - 8 AWG (8.4 mm2) or larger.
2.When grounding the generator (Figure 3) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3.NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
NOTE
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 17
DCA-300SSK SERIES — GENERAL INFORMATION
DCA-300SSK FAMILIARIZATION
Generator
The MQ Power DCA-300SSK series generators are
generators
(requires a trailer for transport) power source for telecom
sites, lighting facilities, power tools, submersible pumps and
other industrial and construction machinery.
Engine Control Panel
The “
Engine Control Panel
z
Tachometer
z
Throttle Handle (Up to S/N 3701673)
z
Water Temperature Gauge
z
Oil Pressure Gauge
z
Charging Ammeter Gauge
z
Engine Warning Display Module
z
Engine Speed Switch (S/N 3701674~)
z
Pre-Heat Button
z
Pre-Heat Lamp
z
Emergency Stop Button
z
Battery Switch
z
Auto On/Off Engine Controller (S/N 3701674~)
z
Ignition Switch (Up to S/N 3701673)
Generator Control Panel
The “
Generator Control Panel
z
Output Voltage Adjustment Knob
z
Frequency Meter (Hz)
z
AC Ammeter (Amps)
z
AC Voltmeter (Volts)
z
Ammeter Change-Over Switch
z
Voltmeter Change-Over Switch
z
Panel Light
z
Panel Light Switch
z
Pilot Lamp
Output Terminal Panel
The “
Output Terminal Panel
z
3 auxiliary 240/139V output receptacles, 50 amp
z
3 auxiliary circuit breakers 240V @50 amps
z
2 120V GFCI receptacles, 20 amp
z
2 GFCI circuit breakers 120V@ 20amps
Control Box
The “
Control Box
z
Main Circuit Breaker 800 amps
z
Over-Current Relay
that are designed as a high quality portable
” is provided with the following:
” is provided with the following:
” is provided with the following:
” is provided with the following:
240 kW
Open Delta Excitation System
The DCA-300SSK series generators are equipped with the
state of the art "
delta system consist of an electrically independent winding
wound among stationary windings of the AC output section.
There are four leads: A, B, C and D. During light loads, the
power to the
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load.
Engine
The DCA-300SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D125E-2
The DCA-300SSK2 and DCA-300SSK3 are powered by a 4
cycle, water cooled, air to air after cooled, turbocharged
KOMATSU Model SAA6D125E-2
engines are designed to meet every performance requirement
for the generator. Reference Table 2 for engine specifications.
In keeping with Multiquip's policy of constantly improving its
products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-300SSK series
generators are addressed on the following pages.
Electronic Governor System
The DCA300SSK2 is equipped with an electronic governor
system. It is made up of two parts; an electronic controller
that monitors frequency variation as the load increases and
decreases, and an electronic actuator that controls the engine
throttle. Thr frequency is regulated at ±0.25 to help protect
sensitive equipment.
Microprocessor Engine Control (MPEC)
The DCA300SSK3 incorporates the use of a
engine controller
functions and also allows the generator to operate in an
unattended mode.
Open-Delta
Automatic Voltage Regulator
" excitation system. The open
(AVR) is supplied
fixed ceiling
diesel
" and responds
diesel
engine.
engine. These
microprocessor
unit (MPEC), which monitors basic engine
PAGE 18 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — MAJOR COMPONENTS
Figure 5. Major Components
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DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 19
DCA-300SSK — GENERATOR CONTROL PANEL
S/N 3701673 and Below
S/N 3701674 and Above
Figure 6. Generator Control Panel
PAGE 20 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-300SSK
1.Pilot Lamp – Indicates that the generator is working
properly.
2.Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
3.Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
4.AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
5.AC Voltmeter – Indicates the single phase output
voltage present at the UVWO terminals.
6.Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals,
or to be switched off.
7.Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
8.Panel Light Switch – When activated will turn on control
panel light.
9.Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
This controller has a vertical row of status LED's (inset),
that when lit, indicate that an
engine malfunction (fault), has
been detected. When a fault
has been detected the engine
controller will evaluate the
fault. Any
cause the controller to
shutdown the generator.
“Control Panel”
major
fault will
(Figure 8).
During
engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the controller will shutdown the engine by
initializing the "
Also the engine controller will shutdown the generator in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup. These conditions
can be observed by monitoring the LED status indicators on
the front of the controller module.
A.Off/Manual/Auto Switch – This switch controls the
B.Low Oil Pressure – Indicates the engine pressure
C.High Coolant Temperature – Indicates the engine
cranking cycle
running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the
immediately. If the generator is to be connected to a
building's AC power source via a transfer switch
(isolation), place the switch in the
position the generator will monitor the AC line output
from the building's power source.
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a
temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered a
major
D.Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and duration
are programmable. Typical programmable start settings
is 3 cycles with a 10 second duration . This is considered
a
major
E.Overspeed Shutdown – Indicates the engine is running
at an unsafe speed. This is considered a
, The MPEC will attempt to crank the
Over Speed Protection
manual
fault.
fault.
position, the generator will start
" mode.
auto
position. In this
major
fault.
major
fault.
F.Engine Running – Indicates that engine is running at
a safe operating speed.
11. Main Circuit Breaker – This three-pole, 800 amp main
breaker is provided to protect the UVWO voltage output
terminals from overload.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 21
DCA-300SSK — ENGINE OPERATING PANEL
S/N 3701673 and Below
S/N 3701674 and Above
Figure 7. Engine Operating Panels
PAGE 22 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-300SSK or
Panels”
1.Throttle Handle - This handle controls the speed of
2.Tachometer – Indicates engine speed in RPM’s for 60
3.Engine Warning Display Module – This module
A.Overheat Lamp – This lamp goes ON when
B.Low Oil Pressure Lamp – During normal
C.Low Fuel Level Lamp – When this lamp is
(Figure 7).
the engine (low or high).
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
display’s the following engine failures:
the cooling water temperature rises
abnormally. If the lamp goes ON during
normal operation of the generator, the
emergency shutdown device will stop the
engine automatically.
operation of the generator this lamp should
remain OFF. When the Manual switch is set to the “Manual”
position to start the engine, the lamp will
be lit. After the oil pressure rises after startup the lamp will go OFF. If this lamp is ever lit (ON)
during normal operation of the generator, the emergency
shutdown device will stop the engine automatically.
ON, it is time to stop the engine and add
fuel. Remember to let the engine cool before
adding fuel.
DCA-300SSK2
Auto-OFF/Reset
“Engine Operating
-
4.Oil Pressure Gauge – During normal operation this
gauge be should read in the “GREEN” zone. When
starting the generator the oil pressure mar read a little
bit higher, but after the engine warms up the oil pressure
should return to the green zone.
5.Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
6.Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
7.Fuel Gauge - Indicates amount of diesel fuel available.
8.Pre-Heat Lamp – Indicates that the glow plugs of the
diesel engine are hot and the engine is ready to be
started.
9.Pre-Heat Button – Press and hold this button until the
preheat lamp is lit (ON).
10. Emergency Stop Button – Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a means of stopping the engine.
11. Ignition Switch (Up to S/N3701673) –Four position
switch,
key to start and stop engine.
12. Battery Switch – This switch should be set to the ON
position during normal operation. When the engine has
been stop, place this switch in the OFF position. DONOT turn this switch during normal operation, it could
cause damage to the electrical equipment.
13. Engine Speed Switch (S/N3701674~) – Changes
the speed of the engine rpm’s (low or high).
pre-heat, stop, run
and
start
. Insert ignition
D.Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this lamp
goes ON during normal operation of the
generator, stop the engine and fill the
battery with distilled water to the specified
level.
E.Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this lamp
goes ON during normal operation of the
generator, stop the engine and replace the
air filter.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 23
DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
The “
Output Terminal Panel
the following:
z
Three 240/139V output receptacles, 50 amp
z
Three circuit breakers 240V @50 amps
z
Two 120V GFCI receptacles, 20 amp
z
Two (2) GFCI circuit breakers 120V@ 20 amps
z
Eight (8) output terminal lugs
” (Figure 8) is provided with
Output Terminal Panel
Shown below (Figure 8) is the
up on the cover to gain access to receptacles and terminal
lugs.
NOTE
Output Terminal Panel
Terminal legs “O” and “Ground”
are considered
bonded grounds
, lift
.
Figure 8. Output Terminal Panel
PAGE 24 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
any
receptacles can be accessed in
board
position. Each receptacle is protected by a 20 amp
circuit breaker. These breakers are located directly above
the GFCI receptacles. Remember the load output (current)
of both GFCI receptacles is dependent on the load
requirements of the UVWO terminals.
Pressing the
being tripped. Pressing the "
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
reset
button resets the GFCI receptacle after
Test Button
voltage change-over
" (See Figure 9) in
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
UVWO terminals.
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Figure 11. Voltage Regulator Control Knob
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
(Figure 11) on the
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 240/139 VAC Receptacles
There are three 240/139 VAC, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output
terminal panel. These receptacles can be accessed in any
voltage change-over board
Figure 10. 240/139 VAC Twist-Lock
Auxiliary Receptacles
position.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 25
DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the UVWO terminal
lugs or the convenience receptacles. (See Figure 12). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3pole, 800 amp,
to switch
starting the engine.
main
circuit breaker is provided. Make sure
ALL
circuit breakers to the "OFF" position prior to
Over Current Relay
An
over current relay
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
rent relay must be pressed. The over current relay is located in the control box.
(Figure 13) is connected to the main
reset button
Figure 13. Over Current Relay
on the over cur-
Figure 12. Connecting Loads
Maximum Power Output (KW)
The entire load connected to the UVWO output terminal lugs,
duplex and auxiliary receptacles must not exceed 264 kw in
standby or 240 kw in prime output.
PAGE 26 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
NOTE
starting system of the equipment.
If wattage is not given on the equipment's
NOTE
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
WATTS = VOLTAGE x AMPERAGE
z
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
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When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
z
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
z
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
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DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 27
Before connecting this generator to any building’s electrical
system, a
(transfer) switch
licensed electrician
must install an
. Serious damage to the building’s
isolation
electrical system may occur without this transfer switch.
If 3Ø load (kVA) is not given on
the equipment nameplate,
NOTE
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
DCA-300SSK SERIES — GENERATOR OUTPUTS
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Generator Output Voltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by applying jumpers (6) to the
voltage change-over board
(Figure 14).
Generator Amperage
Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.
To obtain some of the voltages as listed in Table 7 (see
below) will require a fine adjustment using the
(VR)
lator
control knob
located on the control panel.
voltage regu-
Voltage Change-Over Board
The
voltage change-over board
(Figure 14) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
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Figure 14. Voltage Change-Over Board
240V Configuration
CAUTION - CHANGING VOLTAGES
NEVER attempt to place jumper plates on the
change-over board
There exist the possibility of
shock or burn, which can cause severe bodily harm
or even death
while the generator is in operation.
electrocution, electrical
!
voltage
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PAGE 28 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — GENERATOR OUTPUTS/GAUGE READING
Maximum Amps
Table 10 shows the
vide. DO NOT exceed the maximum amps as listed.
maximum
amps the generator can pro-
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Figure 16. AC Voltmeter
spma027
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Change-Over Switch
How to Read the Output Terminal Gauge.
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
When the voltage change-over board is jumpered for 3Ø,
240V operation (See Figure 15), place the
Change-Over Switch
the
AC Ammeter Change-Over Switch
(Figure 16) to the W-U position and
AC Voltmeter
(Figure 18) to the U
Figure 18. AC Ammeter
Change-Over Switch
or W position to read the output on the selected leg.
Figure 17. AC Voltmeter
Gauge
(Volt reading on W-U Lug)
40
20
0
60
75
A
Figure 19. AC Ammeter
(Amp reading on U lug)
The
NOTE
ammeter
gauges are only active when the
and
voltmeter
UVWO terminals are in use.
Figure 15. Voltage Change-Over Board
240V Configuration
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 29
DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the
Voltage Change-Over Board
Voltage Regulator Control Knob
and the adjustment of the
.
Figure 22. Voltage Regulator Knob
Remember the voltage change-over board determines the
range
of the output voltage and can be configured in two
different positions that provide 6 different output voltages at
the UVWO output terminals. The generator is shipped from
the factory in the 240V configuration. The voltage regulator
(VR) allows the user to increase or decrease the selected
1Ø-240V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 20 .
2.Connect the load wires to the UVWO terminals as shown
in Figure 23.
voltage.
3Ø-240V UVWO Terminal Output Voltages
1.Jumper the voltage change-over board for 240V operation
as shown in Figure 20.
Figure 20. Voltage Change-Over Board
240V Configuration
2.Connect the load wires to the UVWO terminals as shown
in Figure 21.
1Ø-139V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 20.
2.Connect the load wires to the UVWO terminals as shown
in Figure 24.
Figure 23. UVWO Terminal Lugs
1Ø-240V Connections
Figure 21. UVWO Terminal Lugs
3Ø-240V Connections
3.Turn the voltage regulator knob (Figure 22) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
PAGE 30 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
Figure 24. UVWO Terminal Lugs
1Ø-139V Connections
DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1.Jumper the voltage change-over board for 480V operation
as shown in Figure 25. This configuration uses 6 jumper
plates in 3 different positions. Remember there are 2
jumper plates at every position. Every jumper plate
must
1Ø-480V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 25.
2.Connect the load wires to the UVWO terminals as shown
in Figure 27.
be used.
Figure 25. Voltage Change-Over Board
480V Configuration
2.Connect the load wires to the UVWO terminals as shown
in Figure 26.
1Ø-277V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 25.
Figure 27. UVWO Terminal Lugs
1Ø-480V Connections
NOTE
Figure 26. UVWO Terminal Lugs
3Ø-480V Connections
ALWAYS make sure that the
connections to the UVWO
terminals are
The possibility of arcing exists,
that could cause a fire.
secure
2.Connect the load wires to the UVWO terminals as shown
in Figure 28.
Figure 28. UVWO Terminal Lugs
1Ø-277V Connections
and tight.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 31
DCA-300SSK SERIES — PRE-SETUP
Circuit Breakers
Fuel Check
To protect the generator from an overload, a 3-pole, 800 amp,
main
circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI
circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp
load
circuit breakers
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch
ALL
circuit breakers to
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
the "OFF" position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
Also verify that the oil level is maintained between the two
REFILLING THE FUEL SYSTEM
notches (Figure 29) on the dipstick. See Table 11 for proper
selection of engine oil.
The DCA300SSK series generators may (if equipped with a
trailer or skid) have a
which consists of an
trailer mounted
can be equipped with a
The skid type fuel system does not use the internal generator
fuel tank.
hot
engine can cause a
double fuel tank system
internal
generator fuel tank, and a
fire
or
explosion
(Figure 30),
.
fuel tank. It is also possible the generator
skid mounted
fuel tank (Figure 31).
Figure 29. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Komatsu Engine Owner's Manual. Oil should be
warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
z
API Service Classification CH-4
z
API Service Classification CG-4
z
API Service Classification CF-4
z
ACEA Specification E3
z
ACEA Specification E2
of fuel tank system.
ALWAYS
fuel.
DONOT fill the fuel tanks beyond their capacities.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
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Figure 30. Double Fuel Tank System
CAUTION - REFUELING THE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
fill the fuel tank with clean and fresh
#2 diesel
PAGE 32 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — PRE-SETUP
CAUTION - REFUELING TRAILER FUEL TANK
Figure 31. Skid Type Fuel Tank System
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1.Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 32.
ALWAYS!
filling secondary internal tank.
fill trailer tank
first
with
#2 diesel fuel
, before
CAUTION - REFUELING THE GENERATOR
ALWAYS
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
2.Trailer Fuel Tank First – The trailer fuel tank is the
place trailer on firm level ground before refueling
Figure 32. Only Fill on Level Ground
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine.
ALWAYS
fill trailer fuel tank (Figure 33) first.
Figure 33. Fuel Tank Filling Order
NOTE
NOTE
ONLY! use
refueling.
Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.
#2 diesel fuel
when
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 33
DCA-300SSK SERIES — PRE-SETUP
3.NEVER overfill trailer fuel tank – It is important to
read the trailer fuel gauge when filling trailer fuel tank.
DO NOT wait for fuel to rise in filler neck. See Figure 34.
Figure 34. Full Trailer Tank
CAUTION - REFUELING THE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated.
4.Once the trailer tank is full, the
secondary inner tank
can be filled (See Figure 35). Notice how the trailer
filler tube level rises when the internal tank is filled.
5.Figure 36 below reflects a full fuel system.
Figure 36. Full Fuel System
Fuel from the engine return line will drain into the secondary
6.
internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.
WARNING - REFUELING SECONDARY FUEL TANK
It is recommended to only fill the internal secondary fuel tank to
3/4 full in order to allow for fuel return, fuel expansion, and to
avoid spillage. See Figure 37 for fuel expansion.
Figure 35. Filling Secondary Internal Fuel Tank
PAGE 34 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
Figure 37. Fuel Expansion
DCA-300SSK SERIES — PRE-SETUP
Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
NOTE
may become coated with deposits and cooling efficiency
will be reduced.
Cleaning the Radiator
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
WARNING - BURN HAZARDS
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of
hot!
coolant exists which
can cause severe burns.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 11 for engine and radiator, coolant capacities. Make
sure the coolant level in the recovery tank is always between
the "H" and the "L" markings.
negative
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Komatsu Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
Komatsu Engine Owner's Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 38) when depressed with the thumb as shown
below.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be
less than 50%.
battery terminal disconnected.
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Operation Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.
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Figure 38. Fan Belt Tension
CAUTION - ROTATING PARTS
NEVER place hands near
the belts or fan while the
generator set is running.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 35
DCA-300SSK SERIES — PRE-SETUP
Battery
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
NOTE
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.
DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions.
Always
keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
CAUTION - BATTERY SERVICING SAFETY
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
treatment compound. Replace battery with only
recommended type battery.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 39) are properly
connected to the battery terminals as shown below. The
RED
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
CAUTION - BATTERY SERVICING SAFETY
Alternator
The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
in short circuit instantaneously resulting the alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
ALWAYS
disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
If the battery cable is connected
incorrectly, electrical damage to
the generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
If any hose (
immediately
If applicable perform the following:
Figure 39. Battery Connections
When connecting battery do the following:
1.NEVER connect the battery cables to the battery
terminals when the
ignition
switch is in either the Pre-
Heat, RUN, or START position. ALWAYS make sure
that the ignition switch is in the STOP position when
connecting the battery.
2.Place a small amount of battery terminal treatment
■
Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial power.
An external power cord will be required. This capability is an
option
■
Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via commercial
power. An external power cord will be required. This capability
is an
compound around both battery terminals. This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
PAGE 36 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
fuel
.
.
option
.
or
oil
) lines are defective replace them
DCA-300SSK SERIES — GEN. START-UP PROCEDURE (MANUAL)
BEFORE STARTING (S/N 3701673 and below)
Steps 1 thru 20 are referenced
NOTE
Figure 40. Engine Operating Panel
S/N 3701673 and Below
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
for Engine Operating Panel S/N
3701673 and below. See Figure
40 below. This unit has an
switch
tion
handle
and a
.
igni-
throttle
ALWAYS have adequate ventilation when operating
Direct exhaust away from nearby personnel.
1.Place the
in the “OFF” position prior to starting the engine.
2. Make sure the the
been configured for the desired output voltage.
3.Connect the load to the
receptacles
connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
door.
4.Tighten terminal nuts securely to prevent load wires from
.
slipping out
5.Close all engine enclosure doors (Figure 42).
main, G.F.C.I.
Figure 42. Main, Aux. and GFCI
Circuit Breakers (OFF)
and
aux.
circuit
breakers (Figure 42)
voltage change-over board
UVWO
as shown in Figure 12. These load
terminals or
has
auxiliary
WARNING - STARTING THE GENERATOR
NEVER!
or
manually start the engine with the
auxiliary
circuit breakers in the ON (closed) position.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 37
main, GFCI
Figure 42. Engine Enclosure Doors
DCA-300SSK SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
6.Set the
position.
battery ON/OFF switch
Figure 43. Battery ON/OFF Switch
(Figure 43) to the “ON”
12. The generator's frequency meter (Figure 48) should be
displaying the 60 cycle output frequency in HERTZ.
7.When starting the generator in COLD weather conditions,
turn the
ignition key
to the “PREHEAT ” position (Figure 44).
13. The generator's AC-voltmeter (Figure 49) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 50) to increase or decrease the
desired voltage.
Figure 44. Ignition Switch (Pre-Heat)
8.Press and hold the engine preheat button (Figure 45)
until the preheat lamp is lit (ON).
Figure 48. Frequency Meter (Hz)
Pre-Heat
Button
Figure 45. Pre-Heat Button/ Lamp
9.Place the
engine throttle control
in the “LOW” position
Pre-Heat
Lamp
(Figure 46).
Figure 46. Engine Throttle Control
10. Turn the ignition key to the “START” position (Figure 47)
and listen for the engine to begin cranking. After the
engine starts release the ignition key.
Figure 47 Engine Ignition Switch
Figure 49. Voltmeter
Figure 50. Voltage Adjust Control Knob
14. The ammeter (Figure 51) will indicate zero amps with no
load applied. When a load is applied, the ammeter will
indicate the amount of current that the load is drawing
from the generator.
Figure 51. Ammeter (No Load)
11. Once the engine has started, let it run for 3-5 minutes,
then turn the throttle handle control (Figure 46) to the
“HIGH” position.
PAGE 38 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
15. The engine oil pressure gauge (Figure 52) will indicate
the oil pressure (kg/ cm
2)
of the engine. Under normal
18. Place the
“ON” position (Figure 55).
operating conditions the oil pressure is approximately
4
8
kg/cm2
0
ENGINE OIL PRESSURE
Figure 52. Oil Pressure Gauge
16. The
coolant temperature gauge
(Figure 53) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (
Green Zone
).
19. Observe the generator's ammeter (Figure 56) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
WATER
TEMP
reading if a load is in use.
main, GFCI
, and
aux
. circuit breakers in the
Figure 55. Main, Aux. and GFCI
Circuit Breakers (ON)
Figure 53. Coolant Temperature Gauge
17. The
tachometer gauge
(Figure 54) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 54. Engine Tachometer Gauge
Figure 56. Ammeter (Load)
20. The generator will run until manually stopped or an
abnormal condition occurs.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 39
DCA-300SSK SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
BEFORE STARTING (S/N 3701674 and above)
Steps 1 thru 8 are referenced
for Engine Operating Panel
NOTE
S/N 3701674 and above. See
Figure 57 below. This unit does
not have an ignition switch or a
throttle handle. It does have an
“
engine speed switch
used in conjunction with the
MPEC unit.
Figure 57. Engine Operating Panel
S/N 3701674 and Above
” that is
4.Place the engine speed switch in the “
(Figure 60)
Figure 60. Engine Speed Switch (Low)
.
5.Place the Auto-Off/Reset-Manual switch in the “
LOW
” position
Manual”
position to start the engine (Figure 61). Once the engine
starts, let the engine run for 1-2 minutes. Listen for any
abnormal noises.
Figure 61. Auto-Off/Reset-Manual Switch
6.Once the engine is warm and the engine is running properly,
place the engine speed switch in the “
HIGH
” position
(Figure 62).
1.Before attempting to start generator, reference steps
1 thru 5 in the “
Operating Panel S/N 3701673 and below.
2.Set the
battery ON/OFF switch
position.
Figure 58. Battery ON/OFF Switch
Before Starting Section
” for Engine
(Figure 58) to the “ON”
Figure 62. Engine Speed Switch (High)
7.Verify that the "Engine Running" status LED on the MPEC
unit (Figure 63) is "ON" (lit) after the engine has been started.
3.Press and hold the engine preheat button (Figure 59)
until the preheat lamp is lit (ON).
Figure 63. Engine Running LED (ON)
Pre-Heat
Button
Pre-Heat
Lamp
8.Continue operating the generator as outlined in steps 11
thru 20 in the “
Operating Panel S/N 3701673 and below.
Figure 59. Pre-Heat Button/ Lamp
Before Starting Section
” for Engine
PAGE 40 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — GEN. START-UP PROCEDURE (AUTO MODE)
Starting (Auto Mode)
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any
building’s electrical system, a
electrician
(transfer) switch
building’s electrical system may occur
without this transfer switch.
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
NOTE
must install an
. Serious damage to the
CAUTION - BACKUP GENERATOR USE
When the generator is set in the
AUTO mode, the generator will
automically start
comercial power falling below a
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
licensed
isolation
in the event of
When starting generator in AUTO mode use the "
Start-up" procedure except where noted (see below).
1.Before attempting to start generator, reference steps
1 thru 5 in the “
Operating Panel S/N 3701673 and below.
2.Set the
position.
3.Set the engine speed switch (Figure 65) to the “High”
position.
4.Place the Off/Manual/Auto switch (Figure 66) on the
MPEC unit to the AUTO position.
Before Starting Section
battery ON/OFF switch
Figure 64. Battery ON/OFF Switch
Figure 65. Engine Speed Switch (High)
(Figure 64) to the “ON”
” for Engine
Manual
WARNING - AUTO MODE MAINTENANCE
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
CAUTION - ENGINE SPEED SWITCH
The
Engine Speed Switch
position when running in the
set the switch in the proper position can result in damage
to your generator when it turns on.
NOTE
must be set to the “High”
Auto-Start
When the MPEC
is placed in the AUTO position,
the engine glow plugs will be
warmed and the engine will start
automatically.
mode. Failing to
Control Switch
Figure 66. Off/Manual Auto Switch (AUTO)
5.Continue operating the generator as outlined in steps 11
thru 19 in the “
Operating Panel S/N 3701673 and below.
Before Starting Section
” for Engine
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 41
DCA-300SSK SERIES — GEN. SHUT-DOWN PROCEDURE (MANUAL)
Engine Shutdown Ignition Key (Up to S/N 3701673)
To shutdown the generator use the following procedure:
1.Place both the MAIN, GFCI and LOAD circuit breakers
Engine Shutdown Controller (S/N 3701674~)
To shutdown the generator use the following procedure:
1.Place both the MAIN, GFCI and LOAD circuit breakers
(Figure 67) to the "OFF position".
2. Place the engine speed switch in the “
3.Let the engine cool by running it for 3-5 minutes with no
Figure 67. Main, Aux. and GFCI
Circuit Breakers (OFF)
4.Place the Auto-Manual/Off/Reset switch (Figure 72) to
2.Place the throttle control (Figure 68) in the “LOW” position.
as shown in Figure 67 to the "OFF position".
LOW
(Figure 71).
Figure 71. Engine Speed Switch (High)
load applied.
the
OFF/Reset
position.
” position
Figure 68. Engine Throttle Control
Figure 72. Auto-Manual Off/Reset Switch
3.Let the engine cool by running it for 3-5 minutes with no
load applied.
4.Place the ignition key (Figure 69) in the “STOP” position.
5.Verify that the
"OFF" (not lit).
6.Remove all loads from the generator.
Figure 69. Ignition Key Switch (STOP position)
5.Remove all loads from the generator.
NEVER stop the engine suddenly except in an emergency.
DO NOT use the emergency stop switch a as method ofshutting down the generator. This switch is ONLY to be
Emergency Shutdown Procedure
used in the event of an emergency.
1.PUSH inward the RED emergency stop button located
on the
engine operating panel
(Figure 70) to turn off
the generator in the event of an emergency. This button
is located on either Engine Operating Panel.
NOTE
generator will not start if the emergency stop button is
engaged.
Figure 70. Emergency Stop Button
all
WARNING -
SHUTTING DOWN THE GENERATOR
status LED on the MPEC display are
To disengage the emergency
stop function, pull the
emergency stop button outward
to its original position. This will
allow the generator to operate
normally. Remember the
PAGE 42 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
NOTE PAGE
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 43
DCA-300SSK SERIES — MAINTENANCE
Use Table 13 shown below as a general checklist to be
performed on a daily basis.
PAGE 44 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — MAINTENANCE
General Inspection
Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel
or oil leaks.
Air Cleaner
Every
50 hours
element.
Outer Element:
1.Loosen wing bolt, remove dust cup, then remove wing
nut and take out element.
2.Clean the inside of the body and cover using a damp
cloth.
3.Blow dry with compressed air (0.69Mpa {7kgf.cm
99.4 PSI} maximum) against the side of the element
along the pleats. Then blow dry against outside along
the pleats, then against inside again.
4.Remove one seal each time the element is cleaned.
5.Replace the outer element after cleaning it 6 times or
after one year. Replace the outer element if indicator is
red even after cleaning it.
6.Check the inner cylinder element clamping nut for
looseness, and retighten if necessary.
: If dust indicator is RED, clean the air cleaner
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
Removing Water from the Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water to
condense. This can be reduced by always keeping the tank
as full as possible.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
2
,
according to the following procedure.
To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.
Service Daily
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
Cleaning the Fuel Strainer
7.If seal washer is damaged or the threads of wing nut are
damaged, replace.
8.Remove evacuator valve and clean it with compressed
air. Reinstall.
Inner element (if equipped)
1.Remove the cover and outer element, then remove the
inner element.
2.Cover the air connector opening (outer side) with clean
cloth or cloth tape.
3.Clean the inside of the body. Remove air connector
opening protection.
4.Install a new inner cylinder element to the cylinder and
tighten the nut.
5.Install element.
6.After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 29.
Check Electric Heater (If equipped)
Before starting in cold weather (once a year), please contact
your Komatsu distributor for inspection. Remove electric
heater from the engine intake manifold and check for
disconnections or dirt. When checking or installing the electric
heater, replace the gasket with a new part.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 45
DCA-300SSK SERIES — MAINTENANCE
DCA-300SSK SERIES — MAINTENANCE
WARNING - BURN HAZARDS
Allow engine to
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
Flushing Out Radiator and Changing Coolant
1.Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2.Turn water filer cap slowly and remove it.
3.Prepare a container to catch the coolant, then open drain
plug of the radiator or heat exchanger and drain plug of
the engine, and drain the coolant.
4.After draining the coolant, close drain plugs and fill with
tap water.
5.When the water level is near the mouth of the water
filler, open drain plugs and start the engine, and run at
low idling. Keep the engine running at low idling and
flush the radiator for about 10 minutes.
6.Adjust the flow of the water flowing in and draining out to
ensure that the radiator is always full during the flushing
operation. While flushing water through the system,
watch carefully the water inlet hose does not come out
of the radiator filler port.
7.After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
8.After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
9.After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.
12. Remove the corrosion resistor (if equipped) and open
valve.
cool
when flushing out
14. Drain the water inside reserve tank, clean the inside of
the reserve tank, then fill with coolant/water mixture to
between the full and low lines.
15. Stop the engine, wait for 3 minutes, add tap water until
the water level reaches near the water filer port, then
tighten the radiator cap.
Changing Oil
1.Make sure the oil is cool before changing.
2.Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
3.Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
4.Using a filter wrench, turn filter cartridge to the left to
remove it. If the filter cartridge is filled with a large
amount of oil, wait 10 minutes or so before removing.
Make sure there is no old gasket stuck on the filter holder.
5.Tighten drain plug. Clean the filter holder, fill the new
filter cartridge with clean engine oil, coat the packing
and thread of the new filter cartridge with engine oil,
then install it to the filter holder. Tighten until the gasket
surface contacts the seal surface of the filter holder,
then tighten it a further 3/4 to 1 turn.
6.Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7.Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
Replacing Fuel Filter
1.Set the container under the filter cartridge to catch fuel.
2.Using a filter wrench, turn the filter cartridge to the left
to remove it.
3.Clean the filter holder, fill the new filter cartridge with
fuel, coat the packing surface of the filter cartridge with
engine oil, then install the cartridge to the filter holder.
4.When installing, tighten until the packing surface
contacts the seal surface of the filter holder then tighten
a further 2/3 of a turn. If the filter cartridge is tighten too
much, the packing will be damaged and will cause fuel
leakage. Fuel leakage will occur if the filter cartridge is
not tightened enough. Always tighten to the correct
angle.
13. Supply water until it flows over the water filler.
PAGE 46 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES — MAINTENANCE
5.After replacing filter cartridge, loosen air bleed plug.
6.Loosen the knob of feed pump, and pump it up and down
until no bubbles come out with the fuel from air bleed
plug.
7.After bleeding the air, tighten air bleed plug, then push in
the knob of feed pump and lock it in position.
9.Screw in valves at the top of the corrosion resistor.
10. Using a filter wrench, turn the cartridge to the left to
remove it.
11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.
12. Tighten until he packing surface contacts the seal
surface of the filter holder, then tighten a further 2/3 of a
turn.
13. Open valves.
Cleaning Breather Element
Generator Storage:
For storage of the generator for over 30 days, the following
is required:
z
Fill the fuel tank completely. Treat with fuel stabilizer if
necessary.
z
Completely drain oil from the crankcase and refill if
necessary with fresh oil.
z
Clean the entire generator, internal and external.
z
Disconnect the negative terminals of the battery and
cover it, or remove it from the generator and store it
separately.
z
If the ambient temperature is expected to drop below
o
0
C, add antifreeze to the radiator.
z
Cover the generator set and store in a clean, dry place
Removal From Long Term Storage:
z
Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.
1.Loosen the clamp, then remove the hose and take out
breather. Wipe off the dirt around the breather. Check
the O-ring, and replace if necessary.
2.Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.
3.Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.
Greasing
1.Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).
z
Remove the oil filler pipe from the turbocharger oil inlet
port, add 0.5-1L (0.13-0.26 gal) of oil to the turbocharger,
reinstall the oil filler pipe.
z
Change the oil in engine oil pan.
z
Replace all the filters.
z
Flush the inside of the cooling system.
z
Drain the water from the fuel tank and bleed the air from
the fuel system.
z
If the engine has not been started for more than one
year, contact your Komatsu distributor to have engine
overhauled.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 47
DCA-300SSK SERIES — MAINTENANCE
Jacket Water Heater and Internal Battery Charger 120
VAC Input Receptacles (OPTIONAL)
This generator is equipped with two 120 VAC, 20 amp input
receptacles located on the output terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the
battery charger
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 73). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in
to apply power to jacket water heater. However, if the
generator will be used in
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power using
an power cord of adequate size.
.
jacket water heate
hot
climates there is no reason
cold
climates it is always a good
r and i
nternal
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
NOTE
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger
.
Figure 73. Battery Charger/Jacket Water
Heater Power Connections
PAGE 48 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES —TRAILER MAINTENANCE
Trailer Maintenance
This section is intended to provide the user with generic
trailer service and maintenance information. The service and
maintenance guidelines referenced in this section refer to a
wide range of trailers.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
The definitions below describe some of the major components
of a typical trailer that would be used with the DCA-400SSVU
Whisperwatt
1.Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when transporting equipment.
2.Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
3.GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4.Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
5.Frame Width - Measurement is from fender to fender
6.Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7.Coupler - Type of hitch used on the trailer for towing.
™
Generator.
8.Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9.Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 18 and Figure 64
and sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches. Please note that some trailers have a double
axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
for lug nut tightening
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 49
DCA-300SSK SERIES —TRAILER MAINTENANCE
Brakes
Trailer brakes should be inspected the
first 200 miles
operation. This will allow the brake shoes and drums to seat
properly. After the first 200 mile interval, inspect the brakes
every 3,000 miles
. If driving over rough terrain, inspect the
Hydraulic Surge Brakes
Hydraulic surge brakes should not require any special
of
attention with the exception of routine maintenance such as
shoe and lining replacement. Brake lines should be
periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 74 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Use Table 14 as a basic trouble shooting guide when brake
problems occur. Please inspect these components as
required using steps 1 through 6 as listed below:
Brake Adjustment
1.Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2.Check the wheel and drum for free rotation.
3.Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4.With a screwdriver or standard adjusting tool, rotate the
Figure 74. Hydraulic Brake Components
star wheel of the adjuster assembly to expand the brake
shoes.
5.Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6.Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7.Replace the adjusting hole cover and lower the trailer to
the ground.
8.Repeat steps 1 through 7 on the remaining brakes.
Actuator
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
Periodically check and test the surge “
sure that it is functioning correctly. Never use an undersize
actuator.
surge
or
actuator
” to make
push
of
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.sgninil
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PAGE 50 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK SERIES —TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
Suspension
The
leaf suspension
(Figure 75) should be visually inspected
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
CAUTION - EYESIGHT HAZARD
ALWAYS
wear safety glasses when
as detailed in Table 16.
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRING TRAILER WHEELS
DO NOT attempt to repair or modify a wheel. DO NOT
install in inner tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
springs and associated components
every 6,000
miles
Figure 75. Major Suspension Components
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are
hot!
. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 15 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
metI).sbL-.tF(euqroT
TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
SNUG FIT ONLY.PARTS MUST ROTATE FREELY
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT
-
BOLT ASSEMBLY
stnemeriuqeReuqroTnoisnepsuS.61elbaT
.
.
05-XAM03-NIM
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 51
DCA-300SSK SERIES —TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 77. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 17.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
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eziSleehWssaPtsriF
SBL-TF
"2152-0204-5356-05
152-0204-5356-05
"3
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
ssaPdnoceS
SBL-TF
ssaPdrihT
SBL-TF
Figure 76. Wheel Lug Nuts Tightening Sequence
NEVER
use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
Use a
torque wrench
lug nuts.
PAGE 52 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
to tighten
DCA-300SSK — TRAILER-WIRING DIAGRAM
Figure 77. Trailer/Towing Vehicle Wiring Diagram
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 53
DCA-300SSK — GENERATOR WIRING DIAGRAM
Figure 78. Generator Wiring Diagram
PAGE 54 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK— ENGINE WIRING DIAGRAM (S/N 3696506 AND BELOW)
Figure 79. Engine Wiring Diagram (S/N 3696506 and Below)
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 55
DCA-300SSK — ENGINE WIRING DIAGRAM (S/N3696507 TO 3701673)
PAGE 56 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK — ENGINE WIRING DIAGRAM (S/N 3701674 AND ABOVE)
Figure 81. Engine Wiring Diagram (S/N 3701674 and Above)
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 57
DCA-300SSK — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 18 (Engine Troubleshooting) as a basic guideline for troubleshooting the engine. If the problem
cannot be remedied, consult our company's business office or service plant.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 59
DCA-300SSK — TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 (Generator Troubleshooting) as a basic guideline for troubleshooting the generator. If the problem
cannot be remedied, consult our company's business office or service plant.
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 61
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.
The contents and part numbers listed in the parts section are
subject to change
guarantee the availibility of the parts listed.
Sample Parts List:
NO.PART NO.PART NAMEQTY. REMARKS
112345BOLT ....................... 1.... INCLUDES ITEMS W/
2
*
2
12347WASHER, 3/8 IN. .... 1 ....
*
312348HOSE .................... A/R .. MAKE LOCALLY
412349BEARING ................ 1 .... S/N 2345B AND ABOVE
NO. Column
Unique Symbols - All items with same unique symbol
, #, +, %, or >) in the number column belong to the same
(
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.
NOTE
without notice
WASHER, 1/4 IN. ...........
When ordering a part that has more
than one item number listed, check
the remarks column for help in
determining the proper part to order.
. Multiquip does not
NOT SOLD SEPARATELY
MQ-45T ONLY
QTY. Column
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
*
Column are listed below. Other additional notes needed to
describe the item can also be shown.
Assembly/Kit
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
Serial Number Break
range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
- All items on the parts list with the same unique
- Used to list an effective serial number
- Indicates that the part is used
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
PAGE 62 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
“Make/Obtain Locally”
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
“Not Sold Separately”
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.
45C2214600104COVER ....................................................... 1 ........ S/N3691259 TO 3706720
460027105016MACHINE SCREW .....................................4 ........ S/N3691259 TO 3706720
47C9221100004HEX. HEAD BOLT2
470040008000LOCK WASHER2
470041208000PLAIN WASHER2
47505015300SNAP RING ................................................2 ........ REPLACES 0080200007
480017108040HEX. HEAD BOLT4
493871824004STOPPER, CONTROL PANEL1
500041206000PLAIN WASHER1
510605010502SNAP PIN1
52C2214500004COVER, CONTROL BOX1
530017108020HEX. HEAD BOLT8
54C2214300004SIDE PANEL, CONTROL BOX1
550017108020HEX. HEAD BOLT4
56C2214400004PANEL, CONTROL BOX1
570017108020HEX. HEAD BOLT8
580017110025HEX. HEAD BOLT4
590601823861ENGINE STOP UNIT, MSA9014 .................1 ........ S/N3696507 TO 3701673
600027104015MACHINE SCREW .....................................2 ........ S/N3696507 TO 3701673
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 71
CONTROL BOX ASSY. (CONT)
DCA-300SSK CONTROL BOX ASSY.
PAGE 72 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK CONTROL BOX ASSY.
CONTROL BOX ASSY. (CONT)
NO.PART NO.PART NAMEQTY.REMARKS
610601823240RECTIFIER, DE4503 ..................... 4 .............. S/N 3696507 TO 3701673
620021004030MACHINE SCREW ........................ 2 .............. S/N 3696507 TO 3701673
620040004000LOCK WASHER ............................. 2 .............. S/N 3696507 TO 3701673
620041204000PLAIN WASHER ............................ 2 .............. S/N 3696507 TO 3701673
630601802149FUSE, 10A ..................................... 1 .............. S/N 3696507 TO 3701673
630601802149FUSE (RIGHT), 10A ...................... 1 .............. S/N 3701674 AND ABOVE
630601806671FUSE (LEFT), 15A ......................... 1 .............. S/N 3701674 AND ABOVE
630601802218HOLDER, FUSE ............................ 1 .............. S/N 3701674 AND ABOVE
640027103020MACHINE SCREW ........................ 2 .............. S/N 3701674 AND ABOVE
650601823732RELAY ........................................... 1 .............. S/N 3696507 TO 3699681
650601827655RELAY ........................................... 1 .............. S/N 3699682 AND ABOVE
650601823109SOCKET ........................................ 1 .............. S/N 3696507 AND ABOVE
650601824400HOLDER ........................................ 1 .............. S/N 3696507 AND ABOVE
660027104020MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE
670601823706RELAY, HE1ADC24V ..................... 1 .............. S/N 3696507 AND ABOVE
680027104015MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE
690601815402TERMINAL BOARD, TS144P......... 1 .............. S/N 3696507 AND ABOVE
700027104020MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE
210191302000SUCTION HOSE ............................................. 1 ......... UP TO S/N 1337973
210191302300SUCTION HOSE ............................................. 1 ......... FROM S/N 1337974
220191302240RETURN HOSE .............................................. 1 ......... UP TO S/N 1337973
220191302800RETURN HOSE .............................................. 1 ......... FROM S/N 1337974
230605515109HOSE BAND4
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 97
DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)
ENCLOSURE ASSY. (UP TO S/N 3708296)
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR,
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART
NUMBER:
THE SERIAL NUMBER MAY BE REQUIRED.
MQGR-GRAY
MQGRN-GREEN
MQW-WHITE
PAGE 98 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)
ENCLOSURE ASSY. (UP TO S/N 3708296)
NO.PART NO.PART NAMEQTY.REMARKS
1C2414000002BASE .............................................................. 1 ......... S/N 1337508 TO 3691258
1C2414000402BASE .............................................................. 1 ......... S/N 3691259 TO 3701673
1C2415000002BASE .............................................................. 1 ......... S/N 3701674 TO 3708296
2C3414100104FLOOR PANEL1
3C2414100004FLOOR PANEL1
40019208020HEX. HEAD BOLT14
5C2414600004DUCT1
5C2494000004LINING ............................................................ 1 ......... TO S/N 3708296
60017108020HEX. HEAD BOLT4
7C2424000402FRONT FRAME .............................................. 1 ......... S/N3691259 TO 3701673
7C2425000202FRONT FRAME .............................................. 1 ......... S/N3701674 TO 3705209
7C2425000212FRONT FRAME .............................................. 1 ......... S/N3705210 TO 3708296
7C2494100003LINING ............................................................ 1 ......... TO S/N 3708296
80019210025HEX. HEAD BOLT8
9C2424200003COVER, FRONT FRAME1
10C2424200104COVER, FRONT FRAME1
10C2494100104LINING1
110019208020HEX. HEAD BOLT26
120845042703FILLER BRACKET1
130019208020HEX. HEAD BOLT4
14C2424200203COVER, FRONT FRAME1
150019208020HEX. HEAD BOLT14
16C2434000102CENTER FRAME ............................................ 1 ......... UP TO S/N 1337973
16C2434000112CENTER FRAME ............................................ 1 ......... S/N 1337974 TO 3708296
170010114050HEX. HEAD BOLT4
170030014000HEX. NUT4
170040014000LOCK WASHER4
170041214000PLAIN WASHER8
180010114040HEX. HEAD BOLT8
180030014000HEX. NUT8
180040014000LOCK WASHER8
180041214000PLAIN WASHER16
19C2444000302REAR FRAME1
19C2494300204LINING1
200019210025HEX. HEAD BOLT4
210017110025HEX. HEAD BOLT3
22C2444300004COVER, REAR FRAME1
22C2494300004LINING1
23C2444300203DUCT .............................................................. 1 ......... TO S/N 3708296
23C2494300304LINING ............................................................ 1 ......... TO S/N 3708296
240207008000HEX. NUT15
25C2444300104PANEL1
25C2494300104LINING1
260017108020HEX. HEAD BOLT6
270019208020HEX. HEAD BOLT14
DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 99
DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)
ENCLOSURE ASSY. (UP TO S/N 3708296)
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR,
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART
NUMBER:
THE SERIAL NUMBER MAY BE REQUIRED.
MQGR-GRAY
MQGRN-GREEN
MQW-WHITE
PAGE 100 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)
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