Page 1
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA300SSC
60HZ GENERATOR
(CUMMINS QSL9-G3 DIESEL ENGINE)
PARTS LIST NO. C2870300204
Revision #0 (06/25/09)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Page 2
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 3
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could cause
injury or death, you should immediately inform the National Highway Traffi c Safety
Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it fi nds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 3
Page 4
TABLE OF CONTENTS
DCA300SSC
60 Hz Generator
Proposition 65 warning ............................................ 2
Reporting Safety Defects ......................................... 3
Table of Contents ..................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................ 14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ................................... 18-19
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ................................................. 26
Generator Outputs/Gauge Reading ....................... 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Genertor Start-Up Procedure (Manual) ............ 34-35
Generator Start-Up Procedure (Auto Mode) .......... 36
Generator Shut-Down Procedures ........................ 37
Maintenance ..................................................... 38-41
Trailer Maintenance .......................................... 42-45
Trailer Wiring Diagram ........................................... 46
Generator Wiring Diagram ..................................... 47
Engine Wiring Diagram .......................................... 48
Controller Wiring Diagram ..................................... 49
Troubleshooting (Generator) .................................. 50
Troubleshooting (Engine Controller) ...................... 51
Troubleshooting (Diagnostic lamp) ........................ 52
Explanation of Code in Remarks Column.............. 54
Suggested Spare Parts ......................................... 55
Component Drawings
Generator Assembly ......................................... 56-59
Control Box Assembly. ...................................... 60-63
Engine and Radiator Assembly. ........................ 64-67
Engine Operating Panel Assembly. ................... 68-69
Output Terminal Assembly ............................... 70-71
Battery Assembly.............................................. 72-73
Muffl er Assembly. .............................................. 74-75
Fuel Tank Assembly. ......................................... 76-77
Enclosure Assembly ......................................... 78-83
Rubber Seals Assembly ................................... 84-85
Nameplate and Decals Assembly ..................... 86-89
Terms and Conditions of Sale — Parts ................. 90
PAGE 4 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 5
PARTS ORDERING PROCEDURES
www.mqpower.com
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specifi cation Information
Goto www.multiquip.com and click on
Order Parts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 5
When ordering parts, please supply:
❒ 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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
Page 6
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. 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.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
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SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fi re department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 7
Page 8
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
PAGE 8 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
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SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order 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 mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
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.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 9
Page 10
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 11
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 11
Page 12
Generator Specifi cationsTable 1.
Model
Type
Armature Connection Star with Neutral
Phase
Standby Output
Prime Output
Voltage — 1Ø
Voltage — 3Ø
Frequency
Speed
Power Factor
Aux. AC Power
Aux. Voltage/Output
Weight No Fuel
Weight Fuel
Engine Specifi cationsTable 2.
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
4 cycle, water-cooled, direct injection, turbocharged, charge air cooled
19.0 gal. (72.0 L)/hr at full load 15.5 gal. (58.6 L)/hr at 3/4 load
11.1 gal. (41.9 L)/hr at 1/2 load 5.9 gal. (22.4 L)/hr at 1/4 load
Revolving fi eld, self ventilated,
120,127,139, 240, 254 and 277V
208, 220, 240, 416, 440 and 480V
4.49 in. x 5.69 in. (114 mm x 145 mm)
DCA300SSC
Drip proof, Single bearing
3
330 KVA (264 KW)
300 KVA (240 KW)
60 Hz
1800 rpm
0.8
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
8,644 lbs. (3920 kg)
9,769 lbs. (4430 kg)
Cummins QSL9-G3
6 cylinders
543 cu. in. (8900 cc)
363 HP at 1800 rpm
Electric
11.3 gal. (43.0 liters)
7.0 gal. (26.5 liters)
#2 Diesel Fuel
129 gal. (490 liters)
150 Ah x 2 (24V System)
SPECIFICATIONS
PAGE 12 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 13
DIMENSIONS
DimensionsFigure 1.
DimensionsTable 3.
Reference
Letter
A 39.76 in. (1,010 mm) F 43.90 in. (1,115 mm)
B 43.90 in. (1,115 mm) G 149.61 in. (3,800 mm)
C 23.03 in. (585 mm.) H 70.87 in. (1,800 mm)
D 25.20 in. (640 mm) I 55.12 in. (1,400 mm)
E 39.76 in. (1,010 mm)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 13
Page 14
INSTALLATION
PAGE 14 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Typical Generator Grounding ApplicationFigure 2.
Page 15
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
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.
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
specifi es 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:
Use one of the following wire types to connect the 1.
generator to earth ground.
Copper - 10 AWG (5.3 mm2) or larger.a.
Aluminum - 8 AWG (8.4 mm2) or larger.b.
When grounding the generator (Figure 2) connect the 2.
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.
INDOOR INSTALLATION
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 fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor 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.
NEC article 250-52(c) specifi es that the earth ground rod 3.
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 15
Page 16
GENERAL INFORMATION
GENERATOR
The MQ Power Model DCA300SSC is a generator (Figure
3) that is designed as a high quality portable (requires a
trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Emergency Stop Switch
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Pre-Heat Lamp
Engine Speed Switch
Battery Switch
Engine Alarm Lamps (5)
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
Panel Light/Panel Light Switch
3-Pole, 800 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Automatic Voltage Regulator•
Current Transformer•
Over-Current Relay•
Starter Relay•
Engine Controller (Computer Controlled)•
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Eight output terminal lugs (3Ø power)
Battery Charger (Optional)
Water Heater (Optional)
OPEN DELTA EXCITATION SYSTEM
The DCA300SSC generator is equipped with the state of
the art “Open-Delta” excitation system. The open delta
system consist of an electrically independent winding
wound among stationary windings of the AC output
section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectifi ed and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the confi guration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of 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 “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
The DCA300SSC is powered by a 6 cylinder, 4-cycle water
cooled, direct injection, turbocharged, charge air cooled
Cummins QSL9-G3 diesel engine. This engine is designed
to meet every performance requirement for the generator.
Reference Table 2 for engine specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 17
MAJOR COMPONENTS
Generator Major ComponentsTable 4.
ITEM NO. DESCRIPTION
1 Muffl er Assembly
2 Engine Assembly
3 Enclosure Assembly
4 Generator Assembly
5 Output Terminal Assembly
6 Battery Assembly
7 Fuel Tank Assembly
8 Generator Control Panel Assembly
9 Engine Operating Panel Assembly
Major ComponentsFigure 3.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 17
Page 18
GENERATOR CONTROL PANEL
Generator Control PanelFigure 4.
The defi nitions below describe the controls and functions
of the DCA300SSC Generator Control Panel (Figure 4).
Pilot Lamp 1. — Indicates the system is running.
Panel Light 2. — 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.
AC Voltmeter 3. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
Auto On/Off Engine Controller (MPEC) —4.
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
and all major faults will shutdown
the generator. During cranking
cycle, The MPEC will attempt to
crank the 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 Over Speed Protection mode.
Main Circuit Breaker 5. — This three-pole, 800 amp
main breaker is provided to protect the U,V, and W
Output Terminal Lugs from overload.
Voltmeter Change-Over Switch 6. — 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.
Voltage Regulator Control 7. — Allows ±15% manual
adjustment of the generator’s output voltage.
Panel Light Switch 8. — When activated will turn on
control panel light.
Ammeter Change-Over Switch 9. — This switch allows
the AC ammeter to indicate the current fl owing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
AC Ammeter 10. — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
Frequency Meter 11. — Indicates the output frequency
in hertz (Hz). Normally 60 Hz
PAGE 18 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 19
GENERATOR CONTROL PANEL
MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/RESET
position, the unit will not run. When this switch is set to the
manual position, the generator will start 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 AUTO position. In this position, should an
outage occur, the automatic transfer switch (ATS) will
start the generator automatically via the generator’s autostart contacts conn ected to the ATS’s start contacts.
Please refer to your ATS installation manual for further
instructions for the correct installation of the auto-start
contacts of the geerator to the ATS.
Low Oil Pressure — Indicates the engine pressure
has fallen below a safe operating level. The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
High Coolant Temperature — Indicates the engine
temperature has exceeded a safe operating level. The
engine temperature is detected using variable resistive
values from the temperature sending unit. This is
considered a major fault.
The Control Box is equipped with the following major
components:
Over-Current Relay
Voltage Rectifi er (AVR)
Starter Relay
Current Transformer
Voltage Change-Over Board
Three Phase Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
fl owing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 800 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
timesand has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles with
a 10-second duration. This is considered a major fault.
Overspeed Shutdown — Indicates the engine is running
at an unsafe speed. This is considered a major fault.
Engine Running — Indicates that engine is running at
a safe operating speed.
Located behind the generator control panel is the
Generator Control Box. This box contains some of the
necessary electronic components required to make the
generator function.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 19
Page 20
ENGINE OPERATING PANEL
1 2
3 4 5
Engine Operating PanelFigure 5.
The defi nitions below describe the controls and functions
of the DCA300SSC Engine Operating Panel (Figure 5).
Tachometer 1. — Indicates engine speed in RPM’s for 60
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.
Oil Pressure Gauge 2. — During normal operation this
gauge be should read between 28 to 85 psi. (193~586
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
Water Temperature Gauge 3. — During normal operation
this gauge be should read between 167° and 203°F
(75°~95°C).
Charging Ammeter Gauge 4. — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
Fuel Gauge 5. — Indicates amount of diesel fuel available.
Engine Warning Lamps 6. — There are three engine
warning lamps, they are defi ned as follows:
Overheat Lamp a. — This lamp goes ON
when 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.
Low Oil Pressure Lamp b. — During
normal operation of the generator this
lamp should remain OFF. When the
Auto-OFF/Reset-Manual switch is set
6
OILPRESS.
WATERTEMP.
AIRFILTER COOLANT LEVEL
9
OFF
FUELLEVEL
7
8
ON
to the MANUAL position to start the engine, the
lamp will be lit. When the oil pressure rises after
start-up 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.
Low Fuel Level Lamp c. — When this lamp
is ON, it is time to stop the engine and
add fuel. Remember to let the engine cool
before adding fuel.
Air Filter Alarm d. — When the air fi lter
element is clogged, this lamp goes ON
indicating the element should be
immediately cleaned or replaced.
Coolant Level Alarm e. — This lamp
goes ON when the coolant level is
low. If this lamp goes ON while the
engine is in operation, the emergency
shutdown device will automatically stop
the engine.
Engine Speed Switch 7. — This switch controls the
speed of the engine (low/high).
Pre-Heat Lamp 8. — When ECU is placed in AUX
position, pre-heat lamp will be ON. When pre-heat
cycle is completed, lamp will turn OFF.
Emergency Stop Button 9. — 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.
Battery Switch 10. — 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.
PAGE 20 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 21
NOTES
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 21
Page 22
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three (3) 240/139V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
PAGE 22 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Output Terminal PanelFigure 6.
Page 23
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch 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 U, V, and W output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
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 Output Terminal Lugs.
Turn the voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Voltage Regulator Control KnobFigure 9.
G.F.C.I. ReceptacleFigure 7.
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
120/240V Twist-Lock Auxiliary Figure 8.
Receptacles
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 23
Page 24
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 10).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3-pole,
800A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Over Current Relay
An over current relay (Figure 11) is connected to the main
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 reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
Over Current RelayFigure 11.
Connecting LoadsFigure 10.
PAGE 24 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 25
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage 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 infl uenced by the effi ciency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Power Factor By LoadTable 5.
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
Electronic devices, communication
equipment
Common power tools 0.8
1.0
THREE PHASE LOAD
When calculating the power requirements for 3-phase
power use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
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.
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 fl uorescent 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.
Cable Selection (60 Hz, Single Phase Operation)Table 6.
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 25
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
Page 26
GENERATOR OUTPUTS
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 12). To obtain some of the voltages as listed in
Table 7 (see below) will require a fi ne adjustment using
the voltage regulator (VR) control knob located on the
control panel.
Voltage Change-Over Board
The voltage change-over board (Figure 12) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
Maximum Amps
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.
Generator Maximum AmpsTable 8.
Model DCA300SSC
Rated Voltage Maximum Amps
Single Phase 120 Volt 666.7 amps (4 wire)
Single Phase 240 Volt 333.3 amps (4 wire)
Three Phase 240 Volt 722 amps
Three Phase 480 Volt 361 amps
Voltage Change-Over BoardFigure 12.
CAUTION
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
Voltages AvailableTable 7.
Three Phase
(Switchable)
Single Phase
(Switchable)
208V 220V 240V 416V 440V 480V
120V 127V 139V 240V 254V 277V
PAGE 26 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 27
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over
switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, confi gure the
Voltage Change-Over Board (Figure 13) which produces
the desired output voltage.
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 16)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 17). This process can be repeated for
terminals V and W.
AC AmmeterFigure 16.
Change-Over Switch
(Amp reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
AC Ammeter Figure 17.
Voltage Change-Over BoardFigure 13.
240/3
Ø Position
AC Voltmeter Gauge Reading
Place the AC Voltmeter Change-Over Switch (Figure 14)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 15).
AC Voltmeter Figure 14.
Change-Over Switch
(Volt reading on W-U Lug)
AC Voltmeter GaugeFigure 15.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 27
Page 28
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 and the adjustment of
the Voltage Regulator Control Knob.
Remember the voltage change-over board determines the
range of the output voltage and can be confi gured 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 confi guration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
3Ø-240V UVWO Terminal Output Voltages
Jumper the voltage change-over board for 240V 1.
operation as shown in Figure 18.
Turn the voltage regulator knob (Figure 20) clockwise 3.
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required
Voltage Regulator KnobFigure 20.
1Ø-240V UVWO Terminal Output Voltages
Make sure the voltage change-over board is jumpered 1.
for 240V operation as shown in Figure 18.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 21.
Voltage Change-Over Board 240V Figure 18.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 19.
UVWO Terminal Lugs 1Ø-240V Figure 21.
Connections
1Ø-120V UVWO Terminal Output Voltages
Make sure the voltage change-over board is jumpered 1.
for 240V operation as shown in Figure 18.
Adjust voltage regulator knob (Figure 20) for an output 2.
of 208V to obtain 120V at the UVWO terminals.
Connect the load wires to the UVWO terminals as 3.
shown in Figure 22.
UVWO Terminal Lugs Figure 19.
UVWO Terminal Lugs Figure 22. 1Ø-120V
Connections
PAGE 28 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 29
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
Jumper the voltage change-over board for 480V 1.
operation as shown in Figure 23. This confi guration
uses 6 jumper plates in 3 different positions. Remember
there are 2 jumper plates at every position. Every
jumper plate must be used.
Voltage Change-Over Board 480V Figure 23.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 24.
1Ø-480V UVWO Terminal Output Voltages
Make sure the voltage change-over board is jumpered 1.
for 480V operation as shown in Figure 23.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 25.
UVWO Terminal Lugs 1Ø-480V Figure 25.
Connections
1Ø-277V UVWO Terminal Output Voltages
Make sure the voltage change-over board is jumpered 1.
for 480V operation as shown in Figure 23.
UVWO Terminal Lugs 3Ø-480V Figure 24.
Connections
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fi re.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 26.
UVWO Terminal Lugs 1Ø-277V Figure 26.
Connections
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 29
Page 30
INSPECTION/SETUP
CIRCUIT BREAKERS
To protect the generator from an overload, a 3-pole, 800
amp, main circuit breaker is provided to protect the U,V,
and W 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 the OFF position prior to starting
the engine.
LUBRICATION OIL
Fill the engine crankcase with lubricating oil through the
fi ller hole, but DO NOT overfi ll. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 27) on the dipstick. See Table 9 for
proper selection of engine oil.
FUEL CHECK
DANGER
Fuel spillage on a hot engine can cause
a fi re or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refi lling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understand this section should refi ll the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 28). ALWAYS fi ll the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fi ll the fuel
tanks beyond their capacities.
Engine Oil DipstickFigure 27.
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 refi ll with the specifi ed amount of oil as
outlined in the Cummins Engine Owner’s Manual. Oil
should be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classifi cation CC/SC
API Service Classifi cation CC/SD
API Service Classifi cation CC/SE
API Service Classifi cation CC/SF
Recommended Motor OilTable 9.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after fi lling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Internal Fuel Tank SystemFigure 28.
PAGE 30 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 31
INSPECTION/SETUP
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
Level Tanks1. — 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 (Figure 29).
CAUTION
ALWAYS place trailer on fi rm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Open cabinet doors on the “right side” of the generator 2.
(from generator control panel position). Remove fuel
cap and fi ll tank (Figure 30).
Fueling the GeneratorFigure 30.
NEVER overfi ll fuel tank3. — It is important to read the
fuel gauge when fi lling trailer fuel tank. DO NOT wait
for fuel to rise in fi ller neck (Figure 31).
Only Fill on Level GroundFigure 29.
NOTICE
ONLY use #2 diesel fuel when refueling.
Full Fuel TankFigure 31.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 32).
Fuel ExpansionFigure 32.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 31
Page 32
INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
Cummins recommends antifreeze/summer coolant for use in
their engines, which can be purchased in concentrate (and
mixed with 50% demineralized water) or pre-diluted. See the
Cummins Engine Owner’s Manual for further details.
WARNING
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 10 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
The engine may overheat if the radiator fi ns become
overloaded with dust or debris. Periodically clean the
radiator fi ns with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
AIR CLEANER
Periodic cleaning/replacement is necessary. Inspect air
cleaner in accordance with the Cummins Engine Owner’s
Manual.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insuffi cient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
Cummins Engine Owner’s Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 33) when depressed with the thumb as shown
below.
Coolant CapacityTable 10.
Engine and Radiator 15.8 Gal (60 liters)
Reserve Tank N/A
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 11) has been added.
Anti-Freeze Table 11.
Operating Temperatures
Vol %
Anti-Freeze
50 -37 -34
Freezing Point
°C °F
Cleaning the Radiator
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
Fan Belt TensionFigure 33.
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
PAGE 32 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 33
INSPECTION/SETUP
BATTERY
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fl uid level between the specifi ed
marks. Battery life will be shortened, if the fl uid 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 treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
The battery is suffi ciently charged if the specifi c gravity
of the battery fl uid is 1.28 (at 68° F). If the specifi c gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
When connecting battery do the following:
NEVER1. connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
Place a small amount of battery terminal treatment 2.
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
NOTICE
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.
CAUTION
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 34) 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
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Battery ConnectionsFigure 34.
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 can cause corrosion and damage the
alternator.
WIRING
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(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 any hose (fuel or oil) lines are defective replace them
immediately.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 33
Page 34
GENERATOR START-UP PROCEDURE (MANUAL)
T
BEFORE STARTING
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main, GFCI or
auxiliary circuit breakers in the ON (closed) position.
Place the 1. main, G.F.C.I., and aux. circuit breakers (Figure
35) in the OFF position prior to starting the engine.
Main, Aux. and GFCI Figure 35.
Circuit Breakers (OFF)
STARTING (MANUAL)
Place the engine speed switch (Figure 37) in the LOW 1.
(down) position.
Engine Speed Switch (Low)Figure 37.
Place the 2. MPEC control switch in the MANUAL
position to start the engine (Figure 38).
MPEC Control Switch Figure 38.
(Manual Position)
Depending on the temperature of the coolant (cold 3.
weather conditions), the pre-heat lamp (Figure 39) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
Make sure the 2. voltage change-over board has been
confi gured for the desired output voltage.
Connect the load to the 3. receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Tighten terminal nuts securely to prevent load wires 4.
from slipping out.
Close all engine enclosure doors (Figure 36).5.
CORRECT
Engine Enclosure DoorsFigure 36.
INCORREC
Pre-Heat ButtonFigure 39.
Once the engine starts, let the engine run for 1-2 4.
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 40) in the HIGH (up)
position.
Engine Speed Switch (High)Figure 40.
Verify that the 5. engine running
status LED on the MPEC unit
(Figure 41) is ON (lit) after the
engine has been started.
PAGE 34 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Engine Running LED (ON)Figure 41.
Page 35
GENERATOR START-UP PROCEDURE (MANUAL)
The generator’s frequency meter (Figure 42) should be 6.
displaying the 60 cycle output frequency in HERTZ.
Frequency MeterFigure 42.
The generator’s AC-voltmeter (Figure 43) will display 7.
the generator’s output in VOLTS. If the voltage is not
within the specified tolerance, use the voltage
adjustment control knob (Figure 44) to increase or
decrease the desired voltage.
VoltmeterFigure 43.
The 10. coolant temperature gauge (Figure 47) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Coolant Temperature GaugeFigure 47.
The11. tachometer gauge (Figure 48) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Engine Tachometer GaugeFigure 48.
Place the 12. main, GFCI, and aux. circuit breakers in the
ON position (Figure 49).
Voltage Adjust Control KnobFigure 44.
The ammeter (Figure 45) will indicate 8. 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.
Ammeter (No Load)Figure 45.
The engine oil pressure gauge (Figure 46) will indicate 9.
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 28 to 85
psi. (193~586 kPa).
Main, Aux. and GFCI Figure 49.
Circuit Breakers (ON)
Observe the generator’s ammeter (Figure 50) and 13.
verify it reads the anticipated amount of current with
respect to the load. The ammeter will only display a
current reading if a load is in use.
Ammeter (Load)Figure 50.
The generator will run until manually stopped or an 14.
abnormal condition occurs.
Oil Pressure GaugeFigure 46.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 35
Page 36
GENERATOR START-UP PROCEDURE (AUTO MODE)
STARTING (AUTO MODE)
DANGER
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
CAUTION
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.
NOTICE
When the generator is set in the AUTO mode, the
generator will automatically start in the event of
commercial power falling below a prescribed level
by means of a contact closure that is generated
automatically by a transfer switch.
When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
Perform steps 1 through 5 in the Before Starting section 1.
as outlined in the Manual Starting Procedure.
Place the 2. engine speed switch (Figure 51) in the
HIGH position
Engine Speed Switch (High)Figure 51.
Place the 3. MPEC Control Switch (Figure 52) in the
AUTO position.
MPEC Control Switch (AUTO)Figure 52.
Continue operating the generator as outlined in the 4.
Manual Start-up procedure (start at step 5).
WARNING
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
The engine speed switch must be set to the “High”
position when running in the auto-start mode. Failing
to set the switch in the proper position can result in
damage to your generator when it turns on.
NOTICE
When the MPEC control switch is placed in the AUTO
position, the engine glow plugs will be warmed and the
engine will start automatically.
PAGE 36 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 37
GENERATOR SHUT-DOWN PROCEDURES
WARNING
NEVER stop the engine suddenly except in an
emergency.
NORMAL SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure:
Place both the 1. MAIN, GFCI and LOAD circuit breakers
as shown in Figure 35 to the OFF position.
Place the engine speed switch (Figure 53) in the “LOW” 2.
(down) position.
Engine Speed Switch (Low)Figure 53.
Let the engine cool by running it at low speed for 3-5 3.
minutes with no load applied.
Place the 4. MPEC Control Switch (Figure 54) to the
OFF/RESET position.
EMERGENCY SHUTDOWN PROCEDURE
To stop the engine in the event of an emergency, 1. PUSH
the emergency stop button (Figure 55) inward. This
button is located on the engine operating panel, see
Figure 5.
Emergency Stop ButtonFigure 55.
MPEC Control Switch (Off/Reset)Figure 54.
Verify that 5. all the status LEDs on the MPEC display
are OFF (not lit).
Remove all loads from the generator.6.
Inspect entire generator for any damage or loosening 7.
of components that may have occurred during
operation.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 37
Page 38
MAINTENANCE
Engine
Generator
2
10 Hrs
DAILY
250 Hrs 500 Hrs
X
X
X
Inspection/MaintenanceTable 12.
Check Engine Fluid Levels X
Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Parts X
Replace Engine Oil and Filter *
Clean Air Filter X
Check Fuel Filter/Water Separator Bowl X
Clean Unit, Inside and Outside X
Change Fuel Filter X
Clean Radiator and Check Coolant Protection Level*
Replace Air Filter Element *
Check all Hoses and Clamps *
Clean Inside of Fuel Tank X
Measure Insulation Resistance Over 3M ohms X
Check Rotor Rear Support Bearing X
*1 Replace engine oil and fi lter at 100 hours, fi rst time only.
*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
*3 Replace primary air fi lter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
with no sags or dips that could collect moisture and/or oil.
1
3
4
1000
Hrs
X
GENERAL INSPECTION
Prior to each use, the generator should be cleaned and
inspected for defi ciencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 14 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 56)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator (Figure 56) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
restriction becomes greater and the dust indicator signal
shows RED meaning the element needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.
PAGE 38 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Air Cleaner/IndicatorFigure 56.
NOTICE
The air fi lter should not be changed until the indicator
reads “RED”. Dispose of old air fi lter. It may not be
cleaned or reused..
Page 39
MAINTENANCE
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
FUEL ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
Cleaning Inside the Fuel Tank
Drain the fuel inside the fuel tank completely. Using a spray
washer (Figure 57) wash out any deposits or debris that
have accumulated inside the fuel tank.
FUEL TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Fuel Tank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
Replace the fuel fi lter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel fi lter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air
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
according to the following procedure. See the Cummins
Engine Manual for details.
Fuel Tank CleaningFigure 57.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 39
Page 40
MAINTENANCE
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
CHECK OIL LEVEL
Check the crankcase oil level prior to each use, or when the
fuel tank is fi lled. Insuffi cient 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 27.
Replacing Oil Filter
Remove the old oil fi lter.
Apply a fi lm of oil to the gasket on the new oil fi lter.
Install the new oil fi lter.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overfl ow
tank and drain.
RADIATOR CLEANING
The radiator (Figure 58) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fi ns or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fi ns and tube.
Radiator CleaningFigure 58.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Tighten both cocks and replace the overfl ow tank.
Replace with coolant as recommended by the engine
manufacturer.
Close radiator cap tightly.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
WARNING
Allow engine to cool when fl ushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
PAGE 40 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Completely drain the oil from the crankcase and refi ll if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
Page 41
MAINTENANCE
JACKET WATER HEATER AND INTERNAL BATTERY
CHARGER 120 VAC INPUT RECEPTACLES
(OPTIONAL)
This generator can be optionally 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 jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 59). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
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.
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 a
power cord of adequate size.
NOTICE
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger..
Battery Charger and Jacket Water Figure 59.
Heater Power Connections
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 41
Page 42
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 generator.
Fuel Cell 1. — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
Braking System 2. — System employed in stopping
the trailer. Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
GVWR 3. — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
Frame Length 4. — Measurement is from the ball hitch
to the rear bumper (refl ector).
Tire Size 8. — 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.
Tire Ply 9. — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Wheel Hub 10. — The wheel hub is connected to the
trailer’s axle.
Tire Rim 11. — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
Lug Nuts 12. — 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 62 for lug nut
tightening and sequence.
Axle 13. — Indicates the maximum weight the axle can
support 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.
Suspension 14. — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-fl ex, and air ride.
Frame Width 5. — Measurement is from fender to
fender
Jack Stand 6. — Trailer support device with maximum
pound requirement from the tongue of the trailer.
Coupler 7. — Type of hitch used on the trailer for
towing.
Electrical 15. — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
Application 16. — Indicates which units can be employed
on a particular trailer.
PAGE 42 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 43
TRAILER MAINTENANCE
BRAKES
Trailer brakes should be inspected the fi rst 200 miles of
operation. This will allow the brake shoes and drums to seat
properly. After the fi rst 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Figure 60 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as listed below:
Brake Adjustment
Place the trailer on jack stands. Make sure the jack 1.
stands are placed on secure level ground.
Check the wheel and drum for free rotation.2.
Remove the adjusting hole cover from the adjusting 3.
slot at the bottom brake backing plate.
With a screwdriver or standard adjusting tool, rotate 4.
the star wheel of the adjuster assembly to expand the
brake shoes.
Adjust the brake shoes outward until the pressure of 5.
the lining against the wheel drum makes the wheel
diffi cult to turn.
Adjust, rotate the star wheel in the opposite direction 6.
until the wheel rotates freely with slight lining drag.
Replace the adjusting hole cover and lower the trailer 7.
to the ground.
Repeat steps 1 through 7 on the remaining brakes.8.
Hydraulic Surge Brakes
Hydraulic surge brakes (Figure 60) should not require any
special attention with the exception of routine maintenance
such as shoe and lining replacement. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Hydraulic Brake ComponentsFigure 60.
Actuator
Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
or push of 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 “actuator” to make sure that
it is functioning correctly. Never use an undersize actuator.
Symptom Possible Cause Solution
No Brakes Brake line broken or kinked? Repair or replace.
Weak Brakes or Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging Brakes
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 43
Hydraulic Brake TroubleshootingTable 13.
Brake lining glazed? Reburnish or replace.
Trailer overloaded? Correct weight.
Brake drums scored or grooved? Machine or replace.
Tire pressure correct? Infl ate all tires equally.
Tires unmatched on the same axle? Match tires.
Brake components loose, bent or
broken?
Brake drums out-of-round? Replace.
System lubricated? Lubricate.
Brake components correct? Replace and correct.
Brake lining thickness incorrect or
not adjusted correctly?
Enough brake fl uid or correct fl uid?
Replace components.
Install new shoes and
linings.
Replace rubber parts
fi ll with dot 4 fl uid.
Page 44
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.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fi tted parts.
Failure to comply may result in serious
injury.
CAUTION
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.
Tire Wear/Infl ation
Suspension
The leaf suspension springs and associated components
(Figure 61) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
Major Suspension ComponentsFigure 61.
Tire infl ation 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 infl ation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Tire Wear TroubleshootingTable 14.
Wear Pattern Cause Solution
Center Wear Over infl ation.
Edge Wear Under infl ation.
Side Wear
Toe Wear Incorrect toe-in. Align wheels.
Cupping Out-of-balance.
Flat Spots
Loss of camber
or overloading.
Wheel lockup and
tire skidding.
Adjust pressure to particular
load per tire manufacturer.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Check bearing adjustment
and balance tires.
Avoid sudden stops when
possible and adjust brakes.
Suspension Torque RequirementsTable 15.
Item Torque (Ft.-Lbs.)
3/8" U-Bolt Min-30 Max-35
7/16" U-Bolt Min-45 Max-60
1/2" U-Bolt Min-45 Max-60
Shackle Bolt
Spring Eye Bolt
Shoulder Type
Shackle Bolt
Snug fi t only. Parts must rotate freely.
Locking nuts or cotter pins are
provided to retain nut-bolt assembly.
Min-30 Max-50
PAGE 44 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 45
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:
Start all wheel lug nuts by hand.1.
Torque all lug nuts in sequence (see Figure 62). 2. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defi ned
by Table 18.
After fi rst road use, retorque all lug nuts in sequence. 3.
Check all wheel lug nuts periodically.
Tire Torque RequirementsTable 16.
Wheel Size
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
TRAILER MAINTENANCE
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 45
Wheel Lug Nuts Figure 62.
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
Page 46
TRAILER WIRING DIAGRAM
PAGE 46 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Trailer/Towing Vehicle Wiring DiagramFigure 63.
Page 47
GENERATOR WIRING DIAGRAM
Generator Wiring DiagramFigure 64.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 47
Page 48
ENGINE WIRING DIAGRAM
PAGE 48 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Engine Wiring DiagramFigure 65.
Page 49
NOTES
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 49
Page 50
TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business offi ce or service plant.
Generator TroubleshootingTable 17.
Symptom Possible Problem Solution
AC Voltmeter defective? Check output voltage using a voltmeter.
Is wiring connection loose? Check wiring and repair.
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
Is AVR defective? Replace if necessary.
Defective Rotating Rectifi er? Check and replace.
Defective Exciter Field? Check for approximately 19 ohms across J & K on CN1
Is engine speed correct? Turn engine throttle lever to “High”.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Short Circuit in load? Check load and repair.
Over current? Confi rm load requirements and reduce.
Defective circuit breaker? Check and replace.
Over current Relay actuated? Confi rm load requirement and replace.
PAGE 50 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 51
TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business offi ce or service plant.
Engine Controller Troubleshooting (MPEC)Table 18.
Symptom Possible Problem Solution
Low oil level? Fill oil level.
Low oil pressure light is on.
Low coolant level light is on.
(Optionally installed)
High coolant temperature
light is on.
Overcrank light is on.
Oil pressure sending unit failure? Replace oil pressure sending unit.
Time delay malfunction in controller? Refer to dealer.
Wire shorted? Inspect/repair wire.
Low coolant level? Fill coolant level.
Sending unit failure? Replace sending unit.
Low battery voltage? Replace/charge battery.
Fan belt tension incorrect? Tighten/replace fan belt.
Air fl ow is not circulating through radiator? Clean/repair radiator grill.
Doors open? Close doors.
Exhaust leaking? Replace/repair gaskets or faulty part.
Generator being overloaded? Check/reduce load.
Thermostat failure? Replace thermostat.
Air intake blocked? Clean all air intakes.
Temperature switch failure Replace temperature switch.
No or low fuel? Fill fuel level.
Controller needs to be calibrated? Refer to dealer.
RPM engine speed too high? Adjust RPM.
Overspeed light is on.
Loss of MPU light(s) or on.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 51
Governor actuator needs to be adjusted? Adjust governor actuator.
Governor controller needs to be adjusted? Adjust governor controller.
Engine controller needs to be calibrated? Refer to dealer.
Magnetic pick up out of adjustment? Adjust magnetic pick up.
Magnetic pick up dirty? Clean magnetic pick up.
Page 52
TROUBLESHOOTING (DIAGNOSTIC LAMP)
The engine controller of this generator diagnoses problems
that arise from the engine control system and the engine
itself. Press the diagnostic button (Figure 66) on the
diagnostic panel to determine if an engine malfunction has
occurred.
Diagnostic PanelFigure 66.
METHOD OF OPERATION
Normally, the diagnostic lamp will be 1. dimly lit when
the MPEC Control Switch is placed in the MANUAL
position.
If engine trouble occurs, the diagnostic lamp will be 2.
brightly lit as long as the control switch is left in the
manual position.
The diagnostic lamp will indicate that an engine 3.
malfunction has occurred.
NOTICE
For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual
NOTICE
If the engine is cranked while the diagnostic switch
is in the “ON” position, the engine will not be stopped
even if the starter switch is turned to the “OFF” position.
In such case, turn the diagnostic switch to the “OFF”
position..
PAGE 52 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 53
NOTES
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 53
Page 54
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.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.
SAMPLE PARTS LIST
NO. PART NO. PART NAME QTY. REMARKS
1 12345 BOLT .....................1 .....INCLUDES ITEMS W/%
2% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY
2% 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY
3 12348 HOSE ..................A/R ...MAKE LOCALLY
4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique
symbol
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 clarifi ed 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 — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Indicated by:
“INCLUDES ITEMS W/(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, which 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.
NOTICE
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.
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 the 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 clarifi ed in the “Remarks” Column.
Serial Number Break — Used to list an effective serial
number 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”
Specifi c Model Number Use — Indicates that the part
is used only with the specifi c model number or model
number variant listed. It can also be used to show a
part is NOT used on a specifi c model or model number
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be 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.
PAGE 54 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 55
DCA300SSC WHISPERWATT GENERATOR WITH
CUMMINGS QSL9-G3 DIESEL ENGINE
1 to 3 units
QTY. P/N DESCRIPTION
1............0602015120 .......... HOSE, RADIATOR UPPER ENGINE
1............0602015121 .......... HOSE, RADIATOR UPPER/LOWER
1............0602015122 .......... HOSE, RADIATOR LOWER
3............0602015244 ..........BELT, FAN
1............4921744 ................ SENSOR, OIL PRESSURE
1............0602122272 .......... OIL PRESSURE UNIT
1............0602123267 ..........WATER TEMPERATURE UNIT
1............0602210189 .......... WATER TEMP. SWITCH ENGINE
1............0602123290 .......... SWITCH, COOLANT LEVEL
6............0810105400 ..........FILTER, FUEL TANK
6............0602042589 .......... FUEL FILTER CARTRIDGE
6............0602042589 ..........CARTRIDGE WATER SEPERATOR
6............0602041224 .......... FILTER, OIL CARTRIDGE
6............0602045193 .......... FILTER, COOLANT CARTRIDGE
3............0602046638 .......... ELEMENT AIR CLEANER OUTER
3............0602046639 .......... ELEMENT AIR CLEANER INNER
1............0601808803 .......... CIRCUIT BREAKER 1P 20A
1............0601808804 .......... CIRCUIT BREAKER 2P 50A
2............LY2DUS24VDC ....RELAY
SUGGESTED SPARE PARTS
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 55
Page 56
GENERATOR ASSY.
PAGE 56 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 57
GENERATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2110000002 ROTOR ASSY ..........................................1 ............. INCLUDES ITEMS W/#
1-1# FIELD ASSY 1
1-2# 0601842402 RESISTOR, 80W 300K 2
1-3# 0601823282 RECTIFIER 1
1-4# 0018205020 HEX HD. CAP SCREW 2
1-4A# 0040005000 WASHER, LOCK 2
1-4B# 0041205000 WASHER, FLAT 2
1-5# 8201070002 FAN 1
1-6# 8201611004 COUPLING DISK 12
1-7# C3164200004 WASHER, COUPLING HUB 1
1-8# 8201015003 BALANCING PLATE .................................1 ............. PURCHASE ITEM 1-11 AS A SET
1-9# 0012116045 HEX HEAD BOLT 10
1-10# 0042616000 WASHER, LOCK 10
1-11# 0601000209 BALANCING WEIGHT KIT 1
1-12# C3112500004 BEARING FLANGE 1
1-13# 0071906315 BEARING 1
2 C2163400003 COUPLING RING 1
3 0343206200 HEX HEAD BOLT 8
4 0043606000 WASHER, LOCK 8
5# 0010312040 HEX HEAD BOLT 12
5A# 0042512000 WASHER, LOCK 12
6 C2130100103 STATOR ASSY 1
6-1 0226200430 RUBBER SEAL 1
6-2 8201323004 CLAMPER 1
6-3 0223300140 RUBBER SEAL 1
6-4 8201323103 CLAMPER 1
6-5 0221200350 RUBBER SEAL 1
6-6 0010110035 HEX HEAD BOLT 2
6-6A 0041210000 WASHER, FLAT 2
6-7 C2132200003 COVER 1
6-8 0226000275 RUBBER SEAL 2
6-9 0225000500 RUBBER SEAL 1
6-10 0017106016 HEX HEAD BOLT 6
6-11 0601850144 GROMMET 1
7 C3154000002 END BRACKET 1
8 C3138000003 FIELD ASSY, EXCITER 1
9 0012110080 HEX HEAD BOLT 4
9 A 0042610000 WASHER, LOCK 4
9 B 0041210000 WASHER, FLAT 4
10 0017112045 HEX HEAD BOLT 8
11 C3154300104 COVER, BEARING 1
12 C3154300004 GASKET, BEARING 1
13 0010106060 HEX HEAD BOLT 4
13A 0040006000 WASHER, LOCK 4
13B 0041206000 WASHER, FLAT 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 57
Page 58
GENERATOR ASSY. (CONTINUED)
PAGE 58 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 59
GENERATOR ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
14 C3154400003 SUCTION COVER 1
15 0017106015 HEX HEAD BOLT 8
16 C3164600103 COUPLING ADAPTER 1
17 0010310030 HEX HEAD BOLT 12
17A 0042510000 WASHER, LOCK 12
18 C2163700004 SPACER, BEARING 1
19 0070506208 BEARING, 6208ZZ 1
20 0010312040 HEX HEAD BOLT 16
20A 0042512000 WASHER, LOCK 16
21 C3132300014 COVER, FAN 1
22 0010106030 HEX HEAD BOLT 1
22A 0041206000 WASHER, FLAT 1
22B 0600815000 NUT 1
23 0605000012 RUBBER SUSPENSION 2
24 0030020000 HEX NUT 4
24A 0040020000 WASHER, LOCK 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 59
Page 60
CONTROL BOX ASSY.
PAGE 60 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 61
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M5213000002 CONTROL BOX 1
2 0601809659 CURRENT TRANSFORMER 3
3 0027106015 MACHINE SCREW 6
4 0601807513 CIRCUIT BREAKER, 800A 1
5 C2261600204 BRACKET, CIRCUIT BREAKER 1
6 0017108020 HEX HEAD BOLT 4
7 0601820604 AUTOMATIC VOLTAGE REGULATOR 1
8 0027106015 MACHINE SCREW 4
9 0601842468 RESISTOR, 5W 150 OHM 1
10 0027103010 MACHINE SCREW 2
11 C2274000103 CHANGE- OVER BOARD, VOLTAGE 1
12 8201852104 CHANGE TERMINAL 10
13 0017108030 HEX HEAD BOLT 20
14 C2277200004 TERMINAL PLATE 3
15 8201853104 CHARGE PLATE 6
16 8201852504 HEX HEAD BOLT 13
17 0801830704 HEX HEAD BOLT 13
18 0040012000 WASHER, LOCK 26
19 0041412000 WASHER, FLAT 26
20 0017110030 HEX HEAD BOLT 4
21 0601820847 OVER CURRENT RELAY 1
22 0601820840 OVER CURRENT RELAY 1
23 0027104016 MACHINE SCREW 2
23A 0207004000 HEX NUT 2
24 0601815153 TERMINAL BOARD 1
25 0027104016 MACHINE SCREW 2
26 0601802218 HOLDER, FUSE 1
26A 0601802149 FUSE (LEFT SIDE), 10A 1
26B 0601802131 FUSE (CENTER), 1A 1
26C 0601802133 FUSE (RIGHT), 5A 1
27 0027103020 MACHINE SCREW 2
28 C3358201704 FUSE HOLDER ASSY 1
28A 0601806644 FUSE, 30A 1
29 0601802410 BRACKET, FUSE HOLDER 1
30 0017106016 HEX HEAD BOLT 1
31 M5260500003 SET PANEL , ELECTRIC PARTS 1
32 0017108020 HEX HEAD BOLT 4
33 LY2DUS24V RELAY .........................................................4 ................REPLACES P/N 0601827655
33A PTF08A SOCKET ......................................................4 ................REPLACES P/N 0601823109
33B PYCA1 HOLDER .....................................................4 ................REPLACES P/N 0601824400
34 0027104020 MACHINE SCREW 8
35 0601823240 RECTIFIER 2
36 0027104020 MACHINE SCREW 2
37 M5260500204 BRACKET 1
38 0602103090 DIAGNOSTIC LAMP 2
36 0027104020 MACHINE SCREW 2
37 M5260500204 BRACKET 1
38 0602103090 DIAGNOSTIC LAMP 2
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 61
Page 62
CONTROL BOX ASSY. (CONTINUED)
PAGE 62 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 63
CONTROL BOX ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
38 A 0601810244 BULB, DC28V 2
39 0601831670 DIAGNOSTIC BUTTON 1
40 0601831205 RESET BUTTON 1
41 0601830746 LOW IDLE SPEED SWITCH 1
42 0601830710 DIAGNOSTIC SWITCH 1
43 0601840009 RHEOSTAT, 2 W 5 k OHM 1
44 0017106016 HEX HEAD BOLT 4
45 0602201455 RELAY, HEATER ............................................. 1 ............... 1210--1004--00
46 0017106016 HEX HEAD BOLT 2
47 C2224000503 CONTROL PANEL 1
48 C2224001504 CONTROL PANEL 1
49 0605011211 PIN 2
50 0601807622 FREQUENCY METER, 45~65Hz 220V 1
51 0601806979 AC AMMETER, 0~1000A 1
52 0601801040 CHANGE- OVER SWITCH, AMMETER 1
53 0601806887 AC VOLTMETER, 0~600V 1
54 0601801041 CHANGE- OVER SWITCH, VOLTMETER 1
55 0601810072 PILOT LAMP 1
55A 0601810261 BULB, 13W 1
56 0601840073 RHEOSTAT (VR), 2W 1K OHM 1
57 0601840121 KNOB 1
58 ECU9988N220V ENGINE CONTROLLER ................................. 1 ...............REPLACES P/N 0602202545
59 0601830765 SWITCH 1
60 0601810171 PANEL LIGHT, DC24V 1
61 0027104020 MACHINE SCREW 2
61A 0207004000 HEX NUT 2
62 0601830710 SWITCH, PANEL LIGHT 1
63 C9221100004 HEX HEAD BOLT 2
63A 0040008000 WASHER, LOCK 2
63B 0041208000 WASHER, FLAT 2
63C 0080200007 SNAP RING 2
64 0017108040 HEX HEAD BOLT 4
65 3871824004 STOPPER, CONTROL PANEL 1
66 0041206000 WASHER, FLAT 1
67 0605010502 SNAP PIN 1
68 C2214500004 COVER, CONTROL BOX 1
69 0017108020 HEX HEAD BOLT 8
70 C2214300004 SIDE PANEL, CONTROL BOX 1
71 0017108020 HEX HEAD BOLT 4
72 C2214400504 PANEL, CONTROL BOX 1
73 0017108020 HEX HEAD BOLT 9
74 0017110025 HEX HEAD BOLT 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 63
Page 64
ENGINE AND RADIATOR ASSY.
PAGE 64 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 65
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2923200204 ENGINE, QSL9-G3 1
1A 0602015244 BELT, FAN ........................................................1 ............. 3288497
1-1 0602046638 ELEMENT, AIR CLEANER (OUTER) ..............1 ............. AF26124
1-1A 0602046639 ELEMENT, AIR CLEANER (INNER) ................1 ............. AF26125
1-2 0602041224 CARTRIDGE, OIL FILTER ...............................1 ............. LF9009
1-3 0602045193 CARTRIDGE, COOLANT FILTER ....................1 ............. WF2076
1-4 0602042588 CARTRIDGE, FUEL FILTER ............................1 ............. FF5580
1-5 0602042589 CARTRIDGE, FUEL WATER SEPARATOR .....1 ............. FS19732
1-6 0602040759 CAP, AIR CLEANER ........................................1 ............. 3013238
1-7 0602040679 DUST SENSOR 1
2 M5303200004 ENGINE FOOT 1
3 0010118050 HEX HEAD BOLT 2
3A 0030018000 HEX NUT 2
3B 0040018000 WASHER, LOCK 2
3C 0041618000 WASHER, FLAT 4
4 0605000011 RUBBER SUSPENSION 2
5 0030016000 HEX NUT 4
5A 0040016000 WASHER, LOCK 4
6 0602012737 RADIATOR / INTER COOLER .........................1 ............. 0920-2216-00
7 0010116050 HEX HEAD BOLT 4
8 0030016000 HEX NUT 4
9 0040016000 WASHER, LOCK 4
10 0041216000 WASHER, FLAT 8
11 C2311101104 BRACKET, RADIATOR 2
12 0017112025 HEX HEAD BOLT 6
13 0602013260 RADIATOR PIPE ..............................................1 ............. 0981-1300-00
14 0602014820 RADIATOR PIPE ..............................................1 ............. 0981-1301-00
15 0602011500 HEX HEAD BOLT .............................................2 ............. 01010-81020
16 0602015120 RADIATOR HOSE, UPPER ENGINE ...............1 ............. 4080544
17 0602015121 RADIATOR HOSE, UPPER/LOWER RAD. ......2 ............. 3283456
18 0602015122 RADIATOR HOSE, LOWER .............................1 ............. 0981-1302-00
19 0602015301 HOSE BAND ...................................................16 ............ 0980-2232-05
20 0602015123 RADIATOR HOSE ............................................1 ............. 0900-1032-00
21 0602015302 HOSE BAND ....................................................2 ............. 0980-2232-10
22 0602015410 CLAMP .............................................................1 ............. 3016478
23 0602011500 HEX HEAD BOLT .............................................1 ............. 01010-81020
24 0602014821 INTER COOLER PIPE .....................................1 ............. 0521-1097-00
25 0602013261 INTER COOLER PIPE .....................................1 ............. 0521-1098-00
26 0602015124 INTER COOLER PIPE .....................................4 ............. 3071049
27 0602015303 HOSE BAND ....................................................8 ............. 3926704
28 0602022563 ADAPTER 1
29 0602022561 90 DEGREE ELBOW 1
30 0603306590 CONNECTOR 1
31 0603300285 ROCKNUT 1
32 0605511395 VALVE 1
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 65
Page 66
ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 66 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 67
ENGINE AND RADIATOR ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
33 0603306395 HOSE JOINT 1
34 0602021070 CAP 1
35 0269200800 DRAIN HOSE 1
36 0602010220 RESERVER TANK ...........................................1 ............. 0921-1223-00
37 0602011023 CAP ..................................................................1 ............. 0920-1125-00
38 813NLU0000T COOLANT LEVEL SWITCH ............................1 ............. REPLACES P/N 0602123290
39 0602011500 HEX HEAD BOLT .............................................4 ............. 01010-81020
40 0602015500 BUSHING .........................................................1 ............. S970B
41 0602013497 HOSE JOINT ...................................................1 ............. 0911-0025-00
42 0602014110 HOSE (L=250) .................................................1 ............. 0980-1310-00
43 0602013498 JOINT ...............................................................1 ............. 0980-1309-00
44 0602014110 HOSE (L=325) .................................................2 ............. 0980-1310-00
45 0602014110 HOSE (L=1100) ...............................................1 ............. 0980-1310-00
46 0602015300 HOSE BAND ....................................................8 ............. 0980-2232-01
47 0193601800 HOSE 1
48 0605515106 HOSE BAND 1
49 0193601100 HOSE 1
50 0193600550 HOSE 1
51 0269501850 HOSE 1
52 0605515067 HOSE BAND 2
53 C2357300003 CLAMPER ROD 1
54 0017112025 HEX HEAD BOLT 1
55 0017116030 HEX HEAD BOLT 1
56 C2357300104 CLAMPER ROD 1
57 0017112025 HEX HEAD BOLT 2
58 0602122272 OIL PRESSURE UNIT 1
59 M9200101504 ADAPTER 1
60 0803000104 PACKING 1
61 0602123267 WATER TEMPERATURE UNIT 1
62 0602015501 ADAPTER ........................................................1 ............. 490519
63 9095720140 PACKING .........................................................1 ............. REPLACES P/N 0602021109
64 0602210189 WATER TEMPERATURE SWITCH ..................1 ............. 3408627
65 0602120481 PICK- UP TACHOMETER 1
66 4993343 ALTERNATOR 1
67 3102763 STARTER 1
68 3973114 WATER PUMP 1
69 3285324D THERMOSTATE W/O-RING 1
70 4921744 SENSOR, OIL PRESSURE 1
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 67
Page 68
ENGINE OPERATING PANEL ASSY.
PAGE 68 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 69
ENGINE OPERATING PANEL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2351101903 OPERATING PANEL 1
2 0017106020 HEX HEAD BOLT 8
3 0207006000 HEX NUT 4
4 0602101000 BATTERY SWITCH 1
5 0021008080 MACHINE SCREW 2
5A 0030004000 HEX NUT 2
5B 0040008000 WASHER, LOCK 2
5C 0041608000 WASHER, FLAT 2
6 0601830710 ENGINE SPEED SWITCH 1
7 0601831557 EMERGENCY STOP BUTTON 1
8 0602120095 TACHOMETER 1
9 0602122093 OIL PRESSURE GAUGE 1
10 0601842450 VOLTAGE DIVIDER 1
11 0602123092 WATER TEMPERATURE GAUGE 1
12 0602121081 CHARGING AMMETER 1
13 0602125091 FUEL GAUGE 1
14 0602103090 ALARM LAMP 5
14A 0601810244 BULB, DC28V 5
15 M5483000003 SET FRAME 1
16 0017110030 HEX HEAD BOLT 2
17 0017110030 HEX HEAD BOLT 3
17A 0030010000 HEX NUT 3
17B 0040010000 WASHER, LOCK 3
17C 0041610000 WASHER, FLAT 6
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 69
Page 70
OUTPUT TERMINAL ASSY.
PAGE 70 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 71
OUTPUT TERMINAL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2231700403 SET BOARD, OUTPUT TERMINAL 1
2 C0277500004 OUTPUT TERMINAL 8
3 0801830904 HEX HEAD BOLT 8
4 0039320000 HEX NUT 16
5 0040020000 WASHER, LOCK 24
6 0041420000 WASHER, FLAT 32
7 3501860604 TERMINAL PLATE 3
8 0019110050 HEX HEAD BOLT 5
8 A 0042310000 WASHER, LOCK 5
8 B 0042410000 WASHER, FLAT 5
9 0601808803 CIRCUIT BREAKER, 1P 20A 2
10 0601808804 CIRCUIT BREAKER, 2P 50A 3
11 C3261600704 BRACKET, CIRCUIT BREAKER 1
11-1 0221200150 RUBBER CUSHION 1
12 0019206020 HEX HEAD BOLT 2
13 0601814013 RECEPTACLE 2
14 0601812565 RECEPTACLE, CS6369 3
15 0025304015 MACHINE SCREW 10
15 A 0207004000 HEX NUT 10
16 C2234500104 COVER 1
17 0019206020 HEX HEAD BOLT 8
18 0601815194 TERMINAL BOARD 1
19 0025304015 MACHINE SCREW 2
20 0601850275 GROMMET 1
21 0601851780 GROMMET 2
22 C2237102303 COVER, OUTPUT TERMINAL 1
23 0019112045 HEX HEAD BOLT 2
24 0042412000 WASHER, FLAT 4
25 0605015604 STAY RUBBER 2
26 0205012000 HEX NUT 2
27 0845043704 SPRING 2
28 C2237101204 COVER 1
29 0017108020 HEX HEAD BOLT 7
30 C2237102403 COVER, OUTPUT TERMINAL 1
31 0019210030 HEX HEAD BOLT 2
32 0845054204 COLLAR 2
33 0805015604 STAY RUBBER 1
34 C2237101504 COVER 1
35 C2237500104 BRACKET 1
36 0017106020 HEX HEAD BOLT 2
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 71
Page 72
BATTERY ASSY.
PAGE 72 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 73
BATTERY ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0165614551 BATTERY 2 145G51
2 C9109100604 BATTERY SHEET 2
3 3972250004 BATTERY BAND 1
4 0805002904 BATTERY BOLT 2
5 0037808000 WING NUT 2
6 0040008000 WASHER, LOCK 2
7 0041608000 WASHER, FLAT 2
8 C2346600404 BATTERY CABLE 1
9 C2346600304 BATTERY CABLE 1
10 C2347600704 BATTERY CABLE 1
11 C2346600504 BATTERY CABLE 1
12 C2346200004 EARTH CABLE 2
13 0347010030 HEX HEAD BOLT 4
14 0208110000 HEX NUT 4
15 0845040414 TERMINAL CAP (+) 2
16 0845041304 TERMINAL CAP (-) 2
17 0017116030 HEX HEAD BOLT 1
18 0040516000 TOOTHED WASHER 1
19 0017112025 HEX HEAD BOLT 1
20 0040512000 TOOTHED WASHER 1
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 73
Page 74
MUFFLER ASSY.
PAGE 74 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 75
MUFFLER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2331100002 MUFFLER 1
2 0019210025 HEX HEAD BOLT 4
3 M5333000003 EXHAUST PIPE 1
4 0602325066 BEND BOLT CLAMP 1
5 C1334200304 GASKET 1
6 0010312055 HEX HEAD BOLT 4
6A 0030312000 HEX NUT 4
6B 0042512000 WASHER, LOCK 4
6C 0041612000 WASHER, FLAT 8
7 C2331300004 COVER 2
8 0017108020 HEX HEAD BOLT 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 75
Page 76
FUEL TANK ASSY.
PAGE 76 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 77
FUEL TANK ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2363000303 FUEL TANK 1
1-1 0810105004 CAP, FUEL TANK 1
1-2 0810105400 FUEL FILTER 1
1-3 0264100525 HOSE, FUEL GAUGE 1
1-4 0605515079 HOSE BAND 2
2 0605503023 FUEL SESOR 1
3 0802120604 PACKING 1
4 0605501093 UNIT, FUEL 1
5 0605516090 PACKING 1
6 0022905015 MACHINE SCREW 5
7 8195523104 TANK BAND 2
8 0805003414 PAD, TANK BAND 4
9 0017108020 HEX HEAD BOLT 4
10 0207308000 SUPER LOCK NUT 2
11 0222100300 TANK SHEET 6
12 0130206000 STREET ELBOW, 1/2" 1
13 0134306170 DRAIN PIPE 1
14 0603325026 VALVE 1
15 0132006000 PLUG, 1/2" 1
16 C1367700304 LOCK PLATE 1
17 0019208020 HEX HEAD BOLT 2
18 0845039604 RUBBER SEAL 1
19 0191503400 SUCTION HOSE 1
20 0191503700 RETURN HOSE 1
21 0605515073 HOSE BAND 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 77
Page 78
ENCLOSURE ASSY.
PAGE 78 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 79
ENCLOSURE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C2413003202 BASE 1
2 C3414100104 FLOOR PANEL 1
3 C2414100004 FLOOR PANEL 1
4 0019208020 HEX HEAD BOLT 14
5 C2414600304 DUCT 1
5A C2494000304 ACOUSTIC SHEET 1
6 0017108020 HEX HEAD BOLT 4
7 M5423000002 FRONT FRAME 1
7A M5493100003 ACOUSTIC SHEET 1
8 M5423000102 FRONT FRAME 1
8A M5493100003 ACOUSTIC SHEET 1
9 0017108020 HEX HEAD BOLT 10
10 0019210025 HEX HEAD BOLT 8
11 C2424200003 COVER, FRONT FRAME 1
12 C2424201504 COVER, FRONT FRAME 1
12A C2494101104 ACOUSTIC SHEET 1
13 0019208020 HEX HEAD BOLT 23
14 0845042703 FILLER BRACKET 1
15 0019208020 HEX HEAD BOLT 4
16 M5433000002 CENTER FRAME 1
17 0010114050 HEX HEAD BOLT 4
17A 0030014000 HEX NUT 4
17B 0040014000 WASHER, LOCK 4
17C 0041214000 WASHER, FLAT 8
18 0010114040 HEX HEAD BOLT 8
18A 0030014000 HEX NUT 8
18B 0040014000 WASHER, LOCK 8
18C 0041214000 WASHER, FLAT 16
19 C2367700404 COVER 1
20 0019208020 HEX HEAD BOLT 2
21 M5443000002 REAR FRAME 1
22 0019210025 HEX HEAD BOLT 4
23 M5443300003 COVER, REAR FRAME 1
23A M5493300004 ACOUSTIC SHEET 1
24 M5443300104 PANEL 1
24A M5493300104 ACOUSTIC SHEET 1
25 0207008000 HEX NUT 12
26 0019208020 HEX HEAD BOLT 14
27 M5453000003 DOOR, REAR FRAME 1
28 M5453000103 DOOR, REAR FRAME 1
29 8225147004 WINDOW PLATE 2
30 0207306000 SELF- LOCKING U NUT 12
31 B9114000102 DOOR HANDLE 1
32 0021806016 MACHINE SCREW 4
32A 0030006000 HEX NUT 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 79
Page 80
ENCLOSURE ASSY. (CONTINUED)
PAGE 80 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 81
ENCLOSURE ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
33 C3444700004 DOOR ROD 1
34 8195146304 DOOR ROD 1
35 0845050704 STAY 4
36 0207006000 HEX NUT 8
37 0805011304 STOPPER, DOOR 1
38 0805011204 STOPPER, DOOR 1
39 0207006000 HEX NUT 4
40 0845047104 HINGE 2
40A 0845045004 WASHER 2
41 0845047204 HINGE 2
41A 0845045004 WASHER 2
42 0019208020 HEX HEAD BOLT 6
43 0601850097 STOPPER 2
44 0025408025 MACHINE SCREW 2
45 0845031504 CAP 4
46 0600800320 MANUAL PAK 1
47 0207006000 HEX NUT 4
48 M5463100002 ROOF PANEL 1
48A M5493500004 ACOUSTIC SHEET 1
49 M3310600004 COVER 1
50 0019208020 HEX HEAD BOLT 4
51 C2464200502 ROOF PANEL 1
51A C2494500904 ACOUSTIC SHEET 1
52 M5423200103 COVER, FRONT FRAME 1
53 0019208020 HEX HEAD BOLT 41
54 M5453200002 SPLASHER PANEL 1
55 0019208065 HEX HEAD BOLT 6
56 M5453000203 SIDE PANEL 1
56A M5493400004 ACOUSTIC SHEET 1
57 M5453000303 SIDE PANEL 1
57A M5493400104 ACOUSTIC SHEET 1
58 M5453000803 SIDE PANEL 1
58A M5493409304 ACOUSTIC SHEET 1
59 M5453000903 SIDE PANEL 1
59A M549340904 ACOUSTIC SHEET 1
60 M5453300004 DUCT 1
60A M5493400204 ACOUSTIC SHEET 1
61 M5453300104 DUCT 1
61A M5493400304 ACOUSTIC SHEET 1
62 M5453300904 DUCT 2
62A M5493409504 ACOUSTIC SHEET 2
63 M5453300204 DUCT 1
63A M5493400404 ACOUSTIC SHEET 1
64 0207008000 HEX NUT 35
65 B9114000002 DOOR HANDLE 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 81
Page 82
ENCLOSURE ASSY. (CONTINUED)
PAGE 82 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 83
ENCLOSURE ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
66 0825007362 DOOR HANDLE 3
67 0021806016 MACHINE SCREW 28
67A 0030006000 HEX NUT 16
68 0845046904 HINGE 5
68A 0845045004 WASHER 5
69 084504700 HINGE 6
69A 0845045004 WASHER 6
70 0019208020 HEX HEAD BOLT 25
71 0601850097 STOPPER 8
72 0025408025 MACHINE SCREW 8
73 0845031504 CAP 11
74 M5463500004 GUTTER 2
75 C2464500304 GUTTER 2
76 0019208020 HEX HEAD BOLT 4
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 83
Page 84
RUBBER SEALS ASSY.
PAGE 84 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 85
RUBBER SEALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0229201400 SEAL RUBBER 4
2 0228901015 SEAL RUBBER 4
3 0228901250 SEAL RUBBER 3
4 0228901310 SEAL RUBBER 3
5 0228900650 SEAL RUBBER 4
6 0228900650 SEAL RUBBER 1
7 0228900710 SEAL RUBBER 1
8 0229201300 SEAL RUBBER 1
9 0221200705 SEAL RUBBER 2
10 0228801210 SEAL RUBBER 2
11 0228100510 SEAL RUBBER 4
12 0228100120 SEAL RUBBER 4
13 0229200470 SEAL RUBBER 2
14 0229201130 SEAL RUBBER 1
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 85
Page 86
NAMEPLATE AND DECALS ASSY.
PAGE 86 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 87
NAMEPLATE AND DECALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1-1 C3550000703 DECAL : HANDLING PROCEDURES ......................... 1 ................. C3500 0070
1-2 C9522100003 DECAL : CAUTION ......................................................2 ................. C9221 0000
CONTROL BOX GROUP
2-1 0800520100 PLATE : ON - OFF........................................................1 ................. AT-202
2-2 0800520904 PLATE : AMMETER CHANGE- OVER SWITCH..........1 ................. N-2438
2-3 0800520814 PLATE : VOLTMETER CHANGE- OVER SWITCH ...... 1 ................. N-2439
2-4 0840624504 DECAL : CIRCUIT BREAKER .....................................1 ................. S-3031
2-5 0840624604 DECAL : PANEL LIGHT SWITCH ................................1 ................. S-3032
2-6 0840624704 DECAL : PILOT LAMP .................................................1 ................. S-3033
2-7 0840624804 DECAL : VOLTAGE REGULATOR ................................ 1 ................. S-3034
2-8 B9531100604 DECAL : WARNING ELECTRIC SHOCK HAZARD ..... 1 ................. B9311 0060
2-9 C0551000903 DECAL : SETTING FOR OUTPUT VOLTAGE .............. 1 ................. C0510 0090
2-10 C2551000004 DECAL : SAFETY INSTRUCTIONS ............................ 1 ................. C2510 0000
2-11 M5560100903 DECAL : WHISPERWATT 300 .....................................1 ................. M5601 0090A
2-12 C9502400004 DECAL : HIGH IDLE SPEED ....................................... 1 ................. C9024 0000
2-13 C9520027704 DECAL : DIAGNOSTIC BUTTON ................................1 ................. C9200 2770
2-14 C9520028604 DECAL : WARNING DIAGNOSTIC LAMP ...................1 ................. C9200 2860
2-15 C9520028704 DECAL : SHUTDOWN DIAGNOSTIC LAMP ............... 1 ................. C9200 2870
2-16 C9520028804 DECAL : LOW IDLE SPEED / DIAG. CODE SW. ......... 1 ................. C9200 2880
2-17 C9521007504 DECAL : DIAGNOSTIC SWITCH .................................1 ................. C9210 0750
2-18 Z0110001504 DECAL : RESET .......................................................... 1 ................. Z0100 0150
ENGINE & RADIATOR GROUP
3-1 6360610304 DECAL : WATER .......................................................... 1 ................. S-1880
3-2 6360620204 DECAL : OIL DRAIN PLUG .........................................1 ................. S-1885
3-3 B9504000404 DECAL : MOVING PARTS ...........................................2 ................. B9040 0040
3-4 B9504100104 DECAL : WARNING HOT COOLANT .......................... 1 ................. B9041 0010
ENGINE OPERATING PANEL GROUP
4-1 C0551000504 DECAL : BATTERY SWITCH ....................................... 1 ................. C0510 0050
4-2 C3550000404 DECAL : ALARM LAMP ...............................................1 ................. C3500 0040
4-3 M5550000503 DECAL : OPERATING PANEL .....................................1 ................. M5500 0050
OUTPUT TERMINAL GROUP
5-1 0840614104 DECAL : GROUND ...................................................... 1 ................. S-2635
5-2 0840619904 DECAL : DANGER HIGH VOLTAGE ............................ 1 ................. S-2731
5-3 9039209064 DECAL : START CONTACT ......................................... 1 ................. S-4468
5-4 B9511100304 DECAL : WARNING ..................................................... 1 ................. B9111 0030
5-5 B9511100404 DECAL : WARNING ELECTRIC SHOCK HAZARD ..... 1 ................. B9111 0040
5-6 B9531100504 DECAL : WARNING ELECTRIC SHOCK HAZARD ..... 1 ................. B9311 0050
5-7 C0551000404 DECAL : 3- PHASE OUTPUT TERMINAL ................... 1 ................. C0510 0040
5-8 C1551000803 DECAL : RECEPTACLE & CIRCUIT BREAKER .......... 1 ................. C1510 0080
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 87
Page 88
NAMEPLATE AND DECALS ASSY. (CONTINUED)
PAGE 88 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 89
NAMEPLATE AND DECALS ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
BATTERY GROUP
6-1 0800689404 DECAL : + ............................................................... 1 ...................... S-2090
6-2 0800689504 DECAL : - ................................................................ 1 ...................... S-2091
6-3 C9505300004 DECAL : CAUTION ................................................. 1 ...................... C9053 0000
MUFFLER GROUP
7-1 A9504000014 DECAL : DANGER ........................................................................... A9040 0001
7-2 B9504200004 DECAL : WARNING ENGINE EXHAUST ................ 1 ...................... B9042 0000
FUEL TANK GROUP
8-1 1320620904 DECAL : DIESEL FUEL .......................................... 1 ...................... S-1756
8-2 6360620004 DECAL : FUEL DRAIN PLUG ................................. 1 ...................... S-1883
8-3 B9504500004 DECAL : WARNING DIESEL FUEL ........................ 1 ...................... B9045 0000
BONNET GROUP
9-1 1320610603 DECAL : WATER - OIL ........................................... 1 ...................... S-1760
9-2 1320621504 DECAL : SUPPORT HOOK .................................... 2 ...................... S-2257
9-3 0840625902 DECAL : MQ ........................................................... 1 ...................... S-3057
9-4 B9504000304 DECAL : CAUTION HOT PARTS ............................ 1 ...................... B9040 0030
9-5 B9531100604 DECAL : WARNING ELECTRIC SHOCK HAZARD 1 ...................... B9311 0060
9-6 0600500090 EMBLEM ................................................................. 2
9-6 A 0021106016 MACHINE SCREW ................................................. 4
9-7 M5560101503 STRIPE ................................................................... 1
9-8 M5560101303 STRIPE ................................................................... 1
9-9 M5560101103 STRIPE ................................................................... 1
9-10 M5560101004 STRIPE ................................................................... 4
9-11 M5560101403 STRIPE ................................................................... 1
9-12 M5560101203 STRIPE ................................................................... 1
9-13 C9504000304 DECAL : CAUTION ................................................. 1 ...................... C9040 0030
9-14 M9504200004 DECAL : WARNING START FIRES ........................ 1 ...................... M9042 0000
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 89
Page 90
TERMS AND CONDITIONS OF SALE — PARTS
r
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
A Returned Material Authorization 1.
must be approved by Multiquip prior to
shipment.
To obtain a Return Material Authorization, 2.
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
The parts numbers and descriptions a.
must match the current parts price
list.
The list must be typed or computer b.
generated.
The list must state the reason(s) c.
for the return.
The list must reference the sales d.
order(s) or invoice(s) under
which the items were originally
purchased.
The list must include the name e.
and phone number of the person
requesting the RMA.
A copy of the Return Material Authorization 3.
must accompany the return shipment.
Freight is at the sender’s expense. All 4.
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
Parts must be in new and resalable 5.
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
The following items are not returnable:6.
Obsolete parts. (If an item is in the a.
price book and shows as being
replaced by another item, it is
obsolete.)
Any parts with a limited shelf life b.
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
Any line item with an extended c.
dealer net price of less than
$5.00.
Special order items.d.
Electrical components.e.
Paint, chemicals, and lubricants.f.
Decals and paper products.g.
Items purchased in kits.h.
The sender will be notified of any material 7.
received that is not acceptable.
Such material will be held for five 8.
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
Credit on returned parts will be issued 9.
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
In cases where an item is accepted, for 10.
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
Credit issued will be applied to future 11.
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
af ter t hat d ate will be bi lled at t he re vise d pri ce.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
SPECIAL E XPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder fo
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
Effective: February 22, 2006
PAGE 90 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)
Page 91
NOTES
DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 91
Page 92
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600 Fax (972) 315-1847
Lewisville, TX 75057
Contact: mqpower@multiquip.com
Web: www.mqpower.com
MQ Parts Department
800-427-1244 Fax: 800-672-7877
310-537-3700 Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2009, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifi cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published
in this publication at any time without notice and without incurring any obligations.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is:
DENYO CO., LTD, JAPAN
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