Multiquip DCA-300SSK User Manual

OPERATION AND PARTS MANUAL

WHISPERWATT

MODELS:

DCA-300SSK DCA-300SSK2 DCA-300SSK3

60 Hz GENERATORS

PARTS LIST NO. C2871300704

SERIAL NO. 3708297~

Revision #4 (03/27/06)

SERIES

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 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,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

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

Specifications Generator/Engine ...................................... 6

Dimensions (Top, Side and Front) ..................................... 7

Safety Alert Messages Symbols ................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals ..................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel (S/N 3701673 and Below) ........ 20

Generator Control Panel (S/N 3701674 and Above) ........ 20

Generator Control Panel Description ............................... 21

Engine Operating Panel (S/N 3701673 and Below) ......... 22

Engine Operating Panel (S/N 3701674 and Above) ........ 22

Engine Operating Panel Description ............................... 23

Output Terminal Panel Overview ................................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Generator Outputs/Gauge Reading ................................. 29

Output Terminal Panel Connections ........................... 30-31

Pre Setup .................................................................. 32-36

Generator Start-up Procedure (Key Switch) .............. 37-39

Generator Start-up Procedure (Manual MPEC) .............. 40

Generator Start-up Procedure (Auto MPEC) .................. 41

Generator Shutdown Procedure ...................................... 42

Maintenance .............................................................. 44-48

Trailer Maintenance.................................................... 49-52

Trailer Wiring Diagram ..................................................... 53

Generator Wiring Diagram ............................................... 54

Engine Wiring Diagram (S/N 3696506 and Below) .......... 55

Engine Wiring Diagram (S/N 3696507 to 3701673) ......... 56

Engine Wiring Diagram (S/N3701674 and Above) ........... 57

Engine Troubleshooting .............................................. 58-59

Generator Troubleshooting .............................................. 60

Engine Contoller Troubleshooting (MPEC) ...................... 61

Explanation of Codes in Remarks Column ..................... 62

Suggested Spare Parts .................................................. 63

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 64-67

Control Box Assembly ............................................... 68-73

Engine & Radiator Assy. (S/N 3697258 & Below ) ..... 74-77

Engine & Radiator Assy. (S/N 3708270-3708296) ..... 78-79

Engine & Radiator Assy. (S/N 3708270 & Above) ..... 80-83

Engine Operating Panel Assembly ............................ 84-85

Output Terminal Assembly ......................................... 86-89

Actuator Assembly .................................................... 90-91

Battery Assembly ...................................................... 92-93

Muffler Assembly ...................................................... 94-95

Fuel Tank Assembly .................................................. 96-97

Enclosure Assembly (S/N 3708296 and Below) ...... 98-103

Enclosure Assembly (S/N 3708297 and Above) .... 104-109

Rubber Seal Assembly .......................................... 110-111

Oil Piping Assembly .............................................. 112-113

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:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 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

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-300SSK SERIES — SPECIFICATIONS

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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

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DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 7

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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

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

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

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

Tachometer

Throttle Handle (Up to S/N 3701673)

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Warning Display Module

Engine Speed Switch (S/N 3701674~)

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Auto On/Off Engine Controller (S/N 3701674~)

Ignition Switch (Up to S/N 3701673)

Generator Control Panel

The “

Generator Control Panel

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Panel Light

Panel Light Switch

Pilot Lamp

Output Terminal Panel

The “

Output Terminal Panel

3 auxiliary 240/139V output receptacles, 50 amp

3 auxiliary circuit breakers 240V @50 amps

2 120V GFCI receptacles, 20 amp

2 GFCI circuit breakers 120V@ 20amps

Control Box

The “

Control Box

Main Circuit Breaker 800 amps

Over-Current Relay

that are designed as a high quality portable

” 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.

10. Microprocessor Engine Controller (MPEC S/N 3701674~)

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.

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. DO NOT 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:

Three 240/139V output receptacles, 50 amp

Three circuit breakers 240V @50 amps

Two 120V GFCI receptacles, 20 amp

Two (2) GFCI circuit breakers 120V@ 20 amps

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

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

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.

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.

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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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)

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

+ 92 hidden pages