MQ Power DCA300SSC-SSCU Generator Operation And Parts Manual

OperatiOn anD parts ManUaL

WhisperWatt™ series

MODeL Dca300ssc

MODeL Dca300sscU

60hz generatOr

(cUMMins qsL9-g3 DieseL engine)

parts List nO. c2870300204 — Dca300ssc parts List nO. c2870300104a — Dca300sscU

Revision #1 (08/10/11)

To find the latest revision of this publication, visit our website at: www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

prOpOsitiOn 65 Warning

Diesel engine exhaust and some of

page 2 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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 Traffic 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 finds 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 1-888-

327-4236 (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 / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11) — page 3

Dca300ssc/Dca300sscU

60 hz generators

Proposition 65 warning ............................................ 2

Reporting Safety Defects ......................................... 3

Table of Contents ..................................................... 4

Parts Ordering Procedures ...................................... 5

Safety Information .............................................. 6-11

Specifications ........................................................ 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

tabLe Of cOntents 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 ............................... 70-74

Battery Assembly (DCA300SSC) ..................... 75-76

Battery Assembly (DCA300SSCU)................... 77-78

Muffler Assembly. .............................................. 79-80

Fuel Tank Assembly (DCA300SSC). ................ 81-82

Fuel Tank Assembly (DCA300SSCU). .............. 83-84

Enclosure Assembly ......................................... 85-91

Rubber Seals Assembly ................................... 92-93

Nameplt.and Decals Assy. (DCA300SSC). ....... 94-97

Nameplt. and Decals Assy. (DCA300SSCU). . 98-101

Terms and Conditions of Sale — Parts ............... 102 page 4 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

Best Deal!

parts OrDering prOceDUres

Ordering parts has never been easier!

Choose from three easy options:

Effective:

January 1 st , 2006

Order via Internet (Dealers Only) :

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Specification Information

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.

Goto www.multiquip.com and click on

Order Parts

to log in and save!

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

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)

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

Order via Phone:

Domestic (US) Dealers Call:

1-800-427-1244

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

International Customers should contact their local Multiquip Representatives for

Parts Ordering information.

When ordering parts, please supply:

❒ Dealer Account Number

❒ Specify Preferred Method of Shipment:

❒ Dealer Name and Address

❒ Shipping Address (if different than billing address)

❒ Return Fax Number

❒ Applicable Model Number

✓ UPS/Fed Ex

■ Priority One

■ Ground

■ Next Day

■ Second/Third Day

✓ DHL

✓ Truck

❒ 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!


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.

safety infOrMatiOn

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.

Warning


CoUlD result in DEATH or SerioUS inJUrY.

CaUtion


CoUlD result in minor or moDerate inJUrY.

NOTICE

Addresses practices not related to personal injury.


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 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.

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.

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.

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

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


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.


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.


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.

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.


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.


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.

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.

safety infOrMatiOn 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.


specificatiOns

model

Type table 1. Generator Specifications

DCA300SSC/DCA300SSCU

Revolving field, self ventilated, open protected type synchronous generator

Star with Neutral Armature Connection

Phase

Standby output prime output

3Ø voltage (l-l/l-n) voltage Change-over Bd. at 3Ø 240/139



Power Factor

Frequency

Speed

Aux. AC Power aux. voltage/output

Dry Weight

Wet Weight model

3

264 KW (330 kVA)

240 KW (300 kVA)

208Y/120, 220Y/127, 240Y/139

416Y/240, 440Y/254, 480Y/277

240/120

0.8

60 Hz

1800 rpm

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

8,644 lbs. (3,920 kg)

9,769 lbs. (4,430 kg)

Table 2. Engine Specifications

Cummins QSL9-G3 Tier 3

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, turbo-charged with air to air after-cooler

6 cylinders

4.49 in. x 5.69 in. (114 mm x 145 mm)

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)

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

150 Ah x 2 (24V System) page 12 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

DiMensiOns

Figure 1. Dimensions reference letter

A

B

C

D

E

Table 3. Dimensions

Dimension in. (mm) reference letter Dimension in. (mm)

39.76 in. (1,010 mm)

43.90 in. (1,115 mm)

23.03 in. (585 mm.)

25.20 in. (640 mm)

39.76 in. (1,010 mm)

H

I

F

G

43.90 in. (1,115 mm)

149.61 in. (3,800 mm)

70.87 in. (1,800 mm)

55.12 in. (1,400 mm)


instaLLatiOn

Figure 2. Typical Generator Grounding Application page 14 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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.

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 firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). Do not remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

instaLLatiOn generator groUnDing

To guard against electrical shock and possible damage to the equipment, it is important to provide a good eartH ground.

Article 250 (Grounding) of the National Electrical Code

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm 2 ) b. Aluminum - 6 AWG (8.4 mm 2 )

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system alWaYS consult with a licensed electrician.

NOTICE

This generator has a permanent bonding conductor between the generator stator windings and the frame.


generator

The MQ Power DCA300SSC and DCA300SSCU generators (Figure 3) are 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)

generaL infOrMatiOn open Delta exCitation SYStem

Each 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 rectified 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 configuration 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 “fixed ceiling” and responds according the demands of the required load.

engine

Both generators are 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 specifications.

In keeping with MQ Power’s policy of constantly improving its products, the specifications 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.


MajOr cOMpOnents

Table 4. generator major Components item no.

1

DeSCription

Muffler Assembly

5

6

7

8

9

2

3

4

Engine Assembly

Enclosure Assembly

Generator Assembly

Output Terminal Assembly

Battery Assembly

Fuel Tank Assembly

Generator Control Panel Assembly

Engine Operating Panel Assembly

Figure 3. Major Components


generatOr cOntrOL paneL

Figure 4. Generator Control Panel

The definitions below describe the controls and functions of the Generator Control Panel (Figure 4).

1. pilot lamp — Indicates the system is running.

2. panel light — Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the oFF position.

3. aC voltmeter — Indicates the output voltage present at the U,v, and W output terminal lugs.

4. auto on/off engine Controller (mpeC) —

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.

5. main Circuit Breaker — This three-pole, 800 amp main breaker is provided to protect the U,v, and W

output terminal lugs from overload.

6. voltmeter Change-over Switch — This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

7. voltage regulator Control — Allows ±15% manual adjustment of the generator’s output voltage.

8. panel light Switch — When activated will turn on control panel light.

9. ammeter Change-over Switch — This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

10. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

11. Frequency meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz page 18 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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.

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.

generatOr cOntrOL paneL

The Control Box is equipped with the following major components:

Over-Current Relay

Voltage Rectifier (AVR)

Starter Relay

Current Transformer

Voltage Change-Over Board

Three Phase Circuit Breaker

NOTICE

Remember the overcurrent relay monitors the current flowing 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).

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.


1 2 3 4 5

engine Operating paneL

6 7 8 9

WATER TEMP.

OIL PRESS.

FUEL LEVEL

AIR FILTER COOLANT LEVEL

ON

OFF

The definitions below describe the controls and functions of the Engine Operating Panel (Figure 5).

1. Tachometer — 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.

2. oil pressure gauge — 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.

3. Water temperature gauge — During normal operation this gauge be should read between 167° and 203°F

(75°~95°C).

4. Charging Ammeter Gauge — Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

5. Fuel Gauge — Indicates amount of diesel fuel available.

6. engine Warning lamps — There are three engine warning lamps, they are defined as follows: a. overheat lamp — 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.

b. low oil pressure lamp — During normal operation of the generator this lamp should remain oFF. When the

auto-oFF/reset-manual switch is set

Figure 5. Engine Operating Panel 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.

c. low Fuel level lamp — When this lamp is ON, it is time to stop the engine and add fuel. Remember to let the engine cool before adding fuel (DCA300SSC only).

d. Air Filter Alarm — When the air filter element is clogged, this lamp goes on indicating the element should be immediately cleaned or replaced.

e. Coolant level alarm — 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.

7. Engine Speed Switch — This switch controls the speed of the engine (low/high).

8. pre-Heat lamp — When ECU is placed in aUx position, pre-heat lamp will be on. When pre-heat cycle is completed, lamp will turn oFF.

9. emergency Stop Button — Push this button inward to stop the engine in the event of an emergency. Do not use this button as a means of stopping the engine.

10. Battery Switch — This switch should be set to the on position during normal operation. When the engine has been stop, place this switch in the oFF position. Do

not turn this switch during normal operation, it could cause damage to the electrical equipment.


nOtes


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)

Figure 6. Output Terminal Panel page 22 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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 change-over

board configuration. 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.

Figure 9. Voltage Regulator Control Knob

Figure 7. G.F.C.I. Receptacle

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 change-over board is configured for

single-phase 240/120 application

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles


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.

Figure 11. Over Current Relay

Figure 10. Connecting Loads page 24 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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 influenced by the efficiency, 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.

table 5. power Factor By load type of load Power Factor

Single-phase induction motors

Electric heaters, incandescent lamps

Fluorescent lamps, mercury lamps

Electronic devices, communication equipment

Common power tools

0.4-0.75

1.0

0.4-0.9

1.0

0.8

2.5

5

7.5

10

15

20

Table 6. Cable Selection (60 Hz, Single phase operation)

Current in

Amperes load in Watts at 100 volts

300

At 200 volts

600

600

900

1200

1200

1800

2400 maximum allowable Cable length

#10 Wire #12 Wire #14 Wire #16 Wire

1000 ft.

500 ft.

350 ft.

250 ft.

600 ft.

300 ft.

200 ft.

150 ft.

375 ft.

200 ft.

125 ft.

100 ft.

1800

2400

3600

4800

150 ft.

125 ft.

100 ft.

75 ft.

65 ft.

50 ft.

CAUTION: Equipment damage can result from low voltage

250 ft.

125 ft.

100 ft.

LOaD appLicatiOn 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 fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

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.


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 fine 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.

generatOr OUtpUts maximum amps

Table 8 shows the maximum amps the generator can provide. Do not exceed the maximum amps as listed.

table 8. generator maximum amps model rated voltage

DCA300SSC

DCA300SSCU 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

Figure 12. Voltage Change-Over Board

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!

UvWo output terminal lugs table 7. voltages available voltage Change-over Board

3-phase 240/139v position voltage Change-over Board

3-phase 480/270v position

3Ø line-line 208V 220V 240V 416V 440V

1Ø line-neutral 120V 127V 139V 240V 254V voltage Change-over Board Single-phase 240/120v position

1Ø line-neutral/ line-line

N/A N/A N/A

480V

277V

N/A page 26 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

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, configure 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.

Figure 16. AC Ammeter

Change-Over Switch

Figure 17. AC Ammeter

(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.

Figure 13. Voltage Change-Over Board

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).

Figure 14. AC Voltmeter

Change-Over Switch

Figure 15. AC Voltmeter Gauge

(Volt reading on W-U Lug)


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 configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240v UvWo terminal output voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 18.

3. Turn the voltage regulator knob (Figure 20) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

Figure 20. Voltage Regulator Knob


1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18.

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

Figure 18. Voltage Change-Over Board 240V

Configuration


Figure 21. UVWO Terminal Lugs 1Ø-240V

Connections



2. Adjust voltage regulator knob (Figure 20) for an output of 208V to obtain 120V at the UVWO terminals.


Figure 19. UVWO Terminal Lugs


Connections page 28 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

OUtpUt terMinaL paneL cOnnectiOns


1. Jumper the voltage change-over board for 480V operation as shown in Figure 23. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.




Figure 23. Voltage Change-Over Board 480V

Configuration



Connections





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 fire.


Connections


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 filler hole, but Do not overfill. 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.

Figure 27. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the 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 Classification CC/SC

API Service Classification CC/SD

API Service Classification CC/SE

 API Service Classification CC/SF table 9. recommended motor oil

inspectiOn/setUp

FUel CHeCK

Danger

Fuel spillage on a hot engine can cause a fire or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. never smoke around or near the generator.

refilling the Fuel System

CaUtion

onlY properly trained personnel who have read and understand this section should refill 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 fill the fuel tanks with clean fresh #2 diesel fuel. Do not fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 28. Internal Fuel Tank System page 30 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

refueling procedure:

Warning

Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. level tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 29).

CaUtion

alWaYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.


2. Open cabinet doors on the “right side” of the generator

(from generator control panel position). Remove fuel cap and fill tank (Figure 30).

Figure 30. Fueling the Generator

3. never overfill fuel tank — It is important to read the fuel gauge when filling trailer fuel tank. Do not wait for fuel to rise in filler neck (Figure 31).

Figure 29. Only Fill on Level Ground

NOTICE

onlY use #2 diesel fuel when refueling.

Figure 31. Full Fuel Tank

CaUtion

Do not overFill fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 32).

Figure 32. Fuel Expansion


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.

table 10. Coolant Capacity

Engine and Radiator

Reserve Tank

15.8 Gal (60 liters)

N/A

operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added.

table 11. anti-Freeze operating temperatures

Vol %

Anti-Freeze

Freezing Point

°C °F

50 -37 -34


Cleaning the radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the 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 insufficient 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.

Figure 33. Fan Belt Tension

CaUtion

NEVER place hands near the belts or fan while the generator set is running.

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.


BatterY

This unit is of negative ground Do not connect in reverse.

Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

Do not over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

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.

Figure 34. Battery Connections


When connecting battery do the following:

1. never 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.

2. Place a small amount of battery terminal treatment 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.

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.


generatOr start-Up prOceDUre (ManUaL)

BeFore Starting

CaUtion

The engine’s exhaust contains harmful emissions.

alWaYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

Starting (manUal)

1. Place the engine speed switch (Figure 37) in the LOW

(down) position.

Warning

never manually start the engine with the main, gFCi or

auxiliary circuit breakers in the on (closed) position.

Figure 37. Engine Speed Switch (Low)

2. Place the mpeC control switch in the manUal position to start the engine (Figure 38).

1. Place the main, g.F.C.i., and aux. circuit breakers (Figure

35) in the oFF position prior to starting the engine.

Figure 38. MPEC Control Switch

(Manual Position)

3. Depending on the temperature of the coolant (cold 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.

Figure 35. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been configured for the desired output voltage.

3. Connect the load to the 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.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 36).

Figure 39. Pre-Heat Button

4. Once the engine starts, let the engine run for 1-2 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.

CORRECT INCORRECT

Figure 40. Engine Speed Switch (High)

5. Verify that the engine running status LED on the MPEC unit

(Figure 41) is on (lit) after the engine has been started.

Figure 36. Engine Enclosure Doors

Figure 41. Engine Running LED (ON) page 34 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

generatOr start-Up prOceDUre (ManUaL)

6. The generator’s frequency meter (Figure 42) should be displaying the 60 cycle output frequency in Hertz.

Figure 42. Frequency Meter

7. The generator’s AC-voltmeter (Figure 43) will display the generator’s output in voltS. If the voltage is not within the specified tolerance,

11. The 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).

Figure 47. Coolant Temperature Gauge

12. The 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.

Figure 43. Voltmeter

8. Use the voltage adjustment control knob (Figure 44) to increase or decrease the desired voltage.

Figure 48. Engine Tachometer Gauge

13. Place the main, gFCi, and aux. circuit breakers in the

on position (Figure 49).

Figure 44. Voltage Adjust Control Knob

9. The ammeter (Figure 45) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 49. Main, Aux. and GFCI

Circuit Breakers (ON)

14. Observe the generator’s ammeter (Figure 50) and 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.

Figure 45. Ammeter (No Load)

10. The engine oil pressure gauge (Figure 46) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 28 to 85 psi. (193~586 kPa).

Figure 50. Ammeter (Load)

15. The generator will run until manually stopped or an abnormal condition occurs.

Figure 46. Oil Pressure Gauge


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.

When starting generator in aUto mode use the “Manual

Start-up” procedure except where noted (see below).

1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure.

2. Place the engine speed switch (Figure 51) in the

HigH position

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.

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.

Figure 51. Engine Speed Switch (High)

3. Place the mpeC Control Switch (Figure 52) in the

aUto position.

Figure 52. MPEC Control Switch (AUTO)

4. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 5).


generatOr shUt-DOWn prOceDUres

Warning

never stop the engine suddenly except in an emergency.

emergenCY SHUtDoWn proCeDUre

1. To stop the engine in the event of an emergency, PUSH the emergency stop button (Figure 55) inward. This button is located on the engine operating panel, see

Figure 5.

normal SHUtDoWn proCeDUre

To shutdown the generator, use the following procedure:

1. Place both the main, gFCi and loaD circuit breakers as shown in Figure 35 to the oFF position.

2. Place the engine speed switch (Figure 53) in the “LOW”

(down) position.

Figure 55. Emergency Stop Button

Figure 53. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the mpeC Control Switch (Figure 54) to the

oFF/reSet position.

Figure 54. MPEC Control Switch (Off/Reset)

5. Verify that all the status LEDs on the MPEC display are oFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occurred during operation.


Maintenance

table 12. inspection/maintenance

Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

Check for Leaks

Engine

Check for Loosening of Parts

Replace Engine Oil and Filter * 1

Clean Air Filter

Check Fuel Filter/Water Separator Bowl

Clean Unit, Inside and Outside

Change Fuel Filter

Clean Radiator and Check Coolant Protection Level* 2

Replace Air Filter Element * 3

Check all Hoses and Clamps * 4

Clean Inside of Fuel Tank

Generator

Measure Insulation Resistance Over 3M ohms

Check Rotor Rear Support Bearing

* 1 Replace engine oil and filter at 100 hours, first time only.

10 Hrs

DailY

X

X

X

X

X

X

X

250 Hrs 500 Hrs

X

X

X

X

X

X

X

X

1000

Hrs

X

X

* 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

* 3 Replace primary air filter 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.

general inSpeCtion

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 12 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.

NOTICE

Figure 56. Air Cleaner/Indicator

The air filter should not be changed until the indicator reads “reD”. Dispose of old air filter. It may not be cleaned or reused..


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.

Maintenance

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 filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter.

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.

Figure 57. Fuel Tank Cleaning


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 filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 27.

replacing oil Filter

Remove the old oil filter.

Apply a film of oil to the gasket on the new oil filter.

Install the new oil filter.

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 overflow tank and drain.

Check hoses for softening and kinks. Check clamps for signs of leakage.

Tighten both cocks and replace the overflow 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 flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Maintenance 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 fins 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 fins and tube.

Figure 58. Radiator Cleaning

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.

Completely drain the oil from the crankcase and refill 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.


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.

Maintenance

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..

Figure 59. Battery Charger and Jacket Water

Heater Power Connections


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.

1. Fuel Cell — Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System — System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. gvWr — Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame length — Measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width — Measurement is from fender to fender

6. Jack Stand — Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler — Type of hitch used on the trailer for towing.

traiLer Maintenance

8. tire Size — Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply — The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub — The wheel hub is connected to the trailer’s axle.

11. tire rim — Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. lug nuts — Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 16 and Figure 62 for lug nut tightening and sequence.

13. Axle — 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.

14. Suspension — Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical — Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application — Indicates which units can be employed on a particular trailer.


BraKeS

Trailer brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles. If driving over rough terrain, inspect the 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 13 as listed below:

Brake adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 7 on the remaining brakes.


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.

Figure 60. Hydraulic Brake Components

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

No Brakes table 13. Hydraulic Brake troubleshooting

Possible Cause

Brake line broken or kinked?

Brake lining glazed?

Solution

Repair or replace.

Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded?

Brake drums scored or grooved?

Tire pressure correct?

Tires unmatched on the same axle?

Brake components loose, bent or broken?

Brake drums out-of-round?

System lubricated?

Brake components correct?

Brake lining thickness incorrect or not adjusted correctly?

Enough brake fluid or correct fluid?

Correct weight.

Machine or replace.

Inflate all tires equally.

Match tires.

Replace components.

Replace.

Lubricate.

Replace and correct.

Install new shoes and linings.

Replace rubber parts fill with dot 4 fluid.


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 fitted 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/inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation Do

not bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 14 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Wear pattern table 14. tire Wear troubleshooting

Cause

Center Wear Over inflation.

Solution

Adjust pressure to particular load per tire manufacturer.

Edge Wear

Side Wear

Under inflation.

Loss of camber or overloading.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating.

Align wheels.

Toe Wear Incorrect toe-in.

Align wheels.

Cupping

Flat Spots

Out-of-balance.

Check bearing adjustment and balance tires.

Wheel lockup and tire skidding.

Avoid sudden stops when possible and adjust brakes.


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 15.

Figure 61. Major Suspension Components table 15. Suspension torque requirements item torque (Ft.-lbs.)

3/8" U-Bolt

7/16" U-Bolt

Min-30 Max-35

Min-45 Max-60

1/2" U-Bolt

Shackle Bolt

Spring Eye Bolt

Min-45 Max-60

Snug fit only. Parts must rotate freely.

Locking nuts or cotter pins are provided to retain nut-bolt assembly.

Shoulder Type

Min-30 Max-50

Shackle Bolt page 44 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

lug nut torque requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 62). Do

not torque the wheel lug nuts all the way down.

Tighten each lug nut in 3 separate passes as defined by Table 16.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

Wheel Size

12" table 16. tire torque requirements

First Pass

Ft-lBS

20-25

Second Pass

Ft-lBS

35-40

13" 20-25 35-40

14"

15"

16"

20-25

20-25

20-25

50-60

50-60

50-60

Third Pass

Ft-lBS

50-65

50-65

90-120

90-120

90-120


Figure 62. Wheel Lug Nuts

Tightening Sequence

NOTICE

never use an pneumatic air gun to tighten wheel lug nuts.


traiLer Wiring DiagraM

Figure 63. Trailer/Towing Vehicle Wiring Diagram page 46 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

generatOr Wiring DiagraM

Figure 64. Generator Wiring Diagram


engine Wiring DiagraM

Figure 65. Engine Wiring Diagram page 48 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

nOtes


trOUbLeshOOting (generatOr)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant.

Symptom

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped table 17. Generator Troubleshooting

Possible Problem

AC Voltmeter defective?

Solution

Check output voltage using a voltmeter.

Is wiring connection loose?

Check wiring and repair.

Is AVR defective?

Replace if necessary.

Defective Rotating Rectifier?

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?


Defective AVR?


Is wiring connections loose?


Defective AVR?

Short Circuit in load?


Check load and repair.

Over current?

Defective circuit breaker?

Confirm load requirements and reduce.

Check and replace.

Over current Relay actuated? Confirm load requirement and replace.


trOUbLeshOOting (engine cOntrOLLer)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (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 office or service plant.

High coolant temperature light is on.

Symptom

Low oil pressure light is on.

Low coolant level light is on.

(Optionally installed)

Overcrank light is on.

Overspeed light is on.

Loss of MPU light(s) or on.

table 18. engine Controller troubleshooting (mpeC)

Low oil level?

Possible Problem

Oil pressure sending unit failure?

Time delay malfunction in controller?

Wire shorted?

Low coolant level?

Sending unit failure?

Low battery voltage?

Fan belt tension incorrect?

Solution

Fill oil level.

Replace oil pressure sending unit.

Refer to dealer.

Inspect/repair wire.

Fill coolant level.

Replace sending unit.

Replace/charge battery.

Tighten/replace fan belt.

Air flow is not circulating through radiator? Clean/repair radiator grill.

Doors open?

Close doors.

Exhaust leaking?

Generator being overloaded?

Replace/repair gaskets or faulty part.

Check/reduce load.

Thermostat failure?

Air intake blocked?

Temperature switch failure

No or low fuel?

Replace thermostat.

Clean all air intakes.

Replace temperature switch.

Fill fuel level.

Controller needs to be calibrated?

RPM engine speed too high?

Refer to dealer.

Adjust RPM.

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.


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.

Figure 66. Diagnostic Panel

metHoD oF operation

1. Normally, the diagnostic lamp will be dimly lit when the mpeC Control Switch is placed in the manUal position.

2. If engine trouble occurs, the diagnostic lamp will be

brightly lit as long as the control switch is left in the manual position.

3. The diagnostic lamp will indicate that an engine 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..


nOtes


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

(@, #, +, %, 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.

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)”

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.


sUggesteD spare parts

DCa300SSC/DCa300SSCUWHiSperWatt 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 (DCA300SSC)

1............0602123261 ..........WATER TEMPERATURE UNIT (DCA300SSCU)

1............0602210189 ..........WATER TEMP. SWITCH ENGINE

1............0602123290 ..........SWITCH, COOLANT LEVEL

6............0810105400 ..........FILTER, FUEL TANK (DCA300SSC)

6............0602042588 ..........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

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.


generatOr assy.


6-6A

6-7

6-8

6-9

7

8

6-10

6-11

5A#

6

6-1

6-2

6-3

6-4

6-5

6-6

9

9 A

9 B

10

11

12

13

13A

13B

no.

1

1-1#

1-2#

part no.

C2110000002

0601842402

1-3#

1-4#

0601823282

0018205020

1-4A# 0040005000

1-4B# 0041205000

1-5#

1-6#

1-7#

1-8#

8201070002

8201611004

C3164200004

8201015003

1-9# 0012116045

1-10# 0042616000

1-11# 0601000209

1-12# C3112500004

1-13# 0071906315

2

2

3

4

5#

C2163400003

M5163400103

0343206200

0043606000

0010312040

0042512000

C2130100103

0226200430

8201323004

0223300140

8201323103

0221200350

0010110035

0041210000

C2132200003

0226000275

0225000500

0017106016

0601850144

C3154000002

C3138000003

0012110080

0042610000

0041210000

0017112045

C3154300104

C3154300004

0010106060

0040006000

0041206000

generatOr assy.

WASHER, LOCK

HEX HEAD BOLT

WASHER, LOCK

STATOR ASSY

RUBBER SEAL

CLAMPER

RUBBER SEAL

CLAMPER

RUBBER SEAL

HEX HEAD BOLT

WASHER, FLAT

COVER

RUBBER SEAL

RUBBER SEAL

HEX HEAD BOLT

GROMMET

END BRACKET

FIELD ASSY, EXCITER

HEX HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX HEAD BOLT

COVER, BEARING

GASKET, BEARING

HEX HEAD BOLT

WASHER, LOCK

WASHER, FLAT

part name QTY. remarKS

ROTOR ASSY ..........................................1 ............. INCLUDES ITEMS W/#

FIELD ASSY

RESISTOR, 80W 300KW

RECTIFIER

HEX HD. CAP SCREW

WASHER, LOCK

WASHER, FLAT

FAN

COUPLING DISK

1

2

1

2

2

2

1

12

WASHER, COUPLING HUB 1

BALANCING PLATE .................................1 ............. PURCHASE ITEM 1-11 AS A SET

HEX HEAD BOLT

WASHER, LOCK

BALANCING WEIGHT KIT

BEARING FLANGE

1

1

10

10

BEARING 1

COUPLING RING .....................................1 ............. DCA300SSC

COUPLING RING .....................................1 ............. DCA300SSCU

HEX HEAD BOLT

1

1

1

1

12

12

8

8

8

1

4

4

1

4

1

1

4

4

1

4

1

6

1

2

2

2

1

1


generatOr assy. (cOntinUeD)


no. part no.

14 C3154400003

15 0017106015

16 C3164600103

17 0010310030

17A 0042510000

18 C2163700004

19 0070506208

20 0010312040

20A 0042512000

21 C3132300014

22 0010106030

22A 0041206000

22B 0600815000

23 0605000012

24 0030020000

24A 0040020000

generatOr assy. (cOntinUeD)

part name

SUCTION COVER

HEX HEAD BOLT

COUPLING ADAPTER

HEX HEAD BOLT

WASHER, LOCK

SPACER, BEARING

BEARING, 6208ZZ

HEX HEAD BOLT

WASHER, LOCK

COVER, FAN

HEX HEAD BOLT

WASHER, FLAT

NUT

RUBBER SUSPENSION

HEX NUT

WASHER, LOCK

2

4

1

1

4

1

1

16

16

1

1

12

12

QTY.

1

8

1 remarKS


cOntrOL bOx assy.


4

4

2

3

7

8

5

6


1 M5213000002

0601809659

0027106015

0601807513

0601807519

4-1 JGJGJGJGJG

C2261600204

0017108020

0601820604

0027106015

9 0601842468

10 0027103010

11 C2274000103

12 8201852104

13 0017108030

14 C2277200004

15 8201853104

16 8201852504

17 0801830704

18 0040012000

19 0041412000

20 0017110030

21 0601820847

22 0601820840

23 0027104016

23A 0207004000

24 0601815153

25 0027104016

26 0601802218

26A 0601802149

26B 0601802131

26C 0601802133

27 0027103020

28 C3358201704

28A 0601806644

29 0601802410

30 0017106016

31 M5260500003

32 0017108020

33 LY2DUS24V

33A PTF08A

33B PYCA1

34 0027104020

35 0601823240

36 0027104020

37 M5260500204

38 0602103090

36 0027104020

cOntrOL bOx assy.

part name

CONTROL BOX

CURRENT TRANSFORMER

MACHINE SCREW

QTY.

1

3

6 remarKS

CIRCUIT BREAKER, 800A .........................1 ................DCA300SSC

CIRCUIT BREAKER, 800A .........................1 ................DCA300SSCU

BUS BAR ........................................................................DCA300SSCU

BRACKET, CIRCUIT BREAKER

HEX HEAD BOLT

AUTOMATIC VOLTAGE REGULATOR 1

1

4

MACHINE SCREW

RESISTOR, 5W 150 OHM

MACHINE SCREW

CHANGE- OVER BOARD, VOLTAGE

3

6

10

20

2

1

4

1

CHANGE TERMINAL

HEX HEAD BOLT

TERMINAL PLATE

CHARGE PLATE

HEX HEAD BOLT

HEX HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX HEAD BOLT

OVER CURRENT RELAY

OVER CURRENT RELAY

MACHINE SCREW

HEX NUT

TERMINAL BOARD

MACHINE SCREW

HOLDER, FUSE

FUSE (LEFT SIDE), 10A

FUSE (CENTER), 1A

FUSE (RIGHT), 5A

MACHINE SCREW

FUSE HOLDER ASSY

FUSE, 30A

BRACKET, FUSE HOLDER

HEX HEAD BOLT

1

2

4

1

13

13

26

26

2

1

2

1

1

1

1

2

1

1

1

1

SET PANEL , ELECTRIC PARTS

HEX HEAD BOLT

1

4

RELAY .........................................................4 ................REPLACES P/N 0601827655

SOCKET ......................................................4 ................REPLACES P/N 0601823109

HOLDER .....................................................4 ................REPLACES P/N 0601824400

MACHINE SCREW

RECTIFIER

MACHINE SCREW

BRACKET

DIAGNOSTIC LAMP

MACHINE SCREW

8

2

2

1

2

2


cOntrOL bOx assy. (cOntinUeD)



37 M5260500204

38 0602103090

38A 0601810244

39 0601831670

40 0601831205

41 0601830746

42 0601830710

43 0601840009

44 0017106016

45 0602201455

46 0017106016

47 C2224000503

48 C2224001504

49 0605011211

50 0601807622

51 0601806979

52 0601801040

53 0601806887

54 0601801041

55 0601810072

55A 0601810261

56 0601840073

57 0601840121

58 ECU9988N220V

59 0601830765

60 0601810171

61 0027104020

61A 0207004000

62 0601830710

63 C9221100004

63A 0040008000

63B 0041208000

63C 0080200007

64 0017108040

65 3871824004

66 0041206000

67 0605010502

68 C2214500004

69 0017108020

70 C2214300004

71 0017108020

72 C2214400504

73 0017108020

74 0017110025

cOntrOL bOx assy. (cOntinUeD)

part name

BRACKET

DIAGNOSTIC LAMP

BULB, DC28V

DIAGNOSTIC BUTTON

RESET BUTTON

LOW IDLE SPEED SWITCH

DIAGNOSTIC SWITCH

RHEOSTAT, 2W 5k OHM

HEX HEAD BOLT

RELAY, HEATER

HEX HEAD BOLT

CONTROL PANEL

CONTROL PANEL

PIN

FREQUENCY METER, 45~65Hz 220V

1

2

2

1

4

1

1

1

1

QTY.

2

1

1

2

1 remarKS

AC AMMETER, 0~1000A

CHANGE- OVER SWITCH, AMMETER

AC VOLTMETER, 0~600V

CHANGE- OVER SWITCH, VOLTMETER 1

1

1

1

1

PILOT LAMP

BULB, 13W

RHEOSTAT (VR), 2W 1K OHM

KNOB

1

1

1

1

ENGINE CONTROLLER ................................. 1 ...............REPLACES P/N 0602202545

SWITCH 1

1 PANEL LIGHT, DC24V

MACHINE SCREW

HEX NUT

SWITCH, PANEL LIGHT

HEX HEAD BOLT

WASHER, LOCK

WASHER, FLAT

SNAP RING

HEX HEAD BOLT

STOPPER, CONTROL PANEL

WASHER, FLAT

SNAP PIN

COVER, CONTROL BOX

HEX HEAD BOLT

SIDE PANEL, CONTROL BOX

HEX HEAD BOLT

PANEL, CONTROL BOX

HEX HEAD BOLT

HEX HEAD BOLT

4

1

8

1

9

4

1

1

1

1

2

4

2

2

1

2

2

2


engine anD raDiatOr assy.



1 C2923200204

1A 0602015244

1-1 0602046638

1-1A 0602046639

1-2 0602041224

1-3 0602045193

1-4 0602042588

1-5 0602042589

1-6 0602040759

1-7 0602040679

2

3

M5303200004

0010118050

3A 0030018000

3B 0040018000

4

5

3C 0041618000

3C 0041218000

0605000011

0030016000

5A 0040016000

6

7

8

9

0602012737

0010116050

0030016000

0040016000

10 0041216000

11 C2311101104

11 M5310200204

12 0017112025

13 0602013260

14 0602014820

15 0602011500

16 0602015120

17 0602015121

18 0602015122

19 0602015301

20 0602015123

21 0602015302

22 0602015410

23 0602011500

24 0602014821

25 0602013261

26 0602015124

27 0602015303

28 0602022563

29 0602022561

30 0603306590

31 0603300285

32 0605511395

engine anD raDiatOr assy.

part name

ENGINE, QSL9-G3

BELT, FAN

ELEMENT, AIR CLEANER (OUTER)

ELEMENT, AIR CLEANER (INNER)

CARTRIDGE, OIL FILTER

CARTRIDGE, COOLANT FILTER

CARTRIDGE, FUEL FILTER

CARTRIDGE, FUEL WATER SEPARATOR 1

CAP, AIR CLEANER

DUST SENSOR

ENGINE FOOT

HEX HEAD BOLT

HEX NUT

1

1

1

1

1

1

QTY.

1

1

1 remarKS

2

2

1

2

WASHER, LOCK

WASHER, FLAT ...............................................4 ............. DCA300SSC

WASHER, FLAT ...............................................4 ............. DCA300SSCU

RUBBER SUSPENSION

4

8

4

4

4

1

2

4 HEX NUT

WASHER, LOCK

RADIATOR / INTERCOOLER

HEX HEAD BOLT

HEX NUT

WASHER, LOCK

WASHER, FLAT

BRACKET, RADIATOR.....................................2 ............. DCA300SSC

BRACKET, RADIATOR.....................................2 ............. DCA300SSCU

HEX HEAD BOLT

RADIATOR PIPE

RADIATOR PIPE

HEX HEAD BOLT

RADIATOR HOSE, UPPER ENGINE

6

1

RADIATOR HOSE, LOWER

HOSE BAND

RADIATOR HOSE

HOSE BAND

CLAMP

HEX HEAD BOLT

INTER-COOLER PIPE

INTER-COOLER PIPE

INTER-COOLER PIPE

HOSE BAND

ADAPTER

90 DEGREE ELBOW

CONNECTOR

LOCKNUT

VALVE

1

1

1

1

1

4

8

1

1

1

1

1

2

1

16

1

2

1

RADIATOR HOSE, UPPER/LOWER RAD. 2


engine anD raDiatOr assy. (cOntinUeD)



33 0603306395

34 0602021070

35 0269200800

36 0602010220

37 0602011023

38 813NLU0000T

39 0602011500

39 0016910025

40 0602015500

41 0602013497

42 0602014110

43 0602013498

44 0602014110

45 0602014110

46 0602015300

47 0193601800

48 0605515106

49 0193601100

50 0193600550

51 0269501850

52 0605515067

52 0605515149

53 C2357300003

53 M5357300003

54 0017112025

55 0017116030

56 C2357300104

57 0017112025

58 0602122272

59 M9200101504

60 0803000104

60 M9200001104

61 0602123267

61 0602123261

62 0602015501

63 9095720140

64 0602210189

65 0602120481

66 4993343

67 3102763

68 3973114

69 3940632

69A 3945603

70 4921744

engine anD raDiatOr assy. (cOntinUeD)

part name

HOSE JOINT

CAP

DRAIN HOSE

QTY.

1

1

1 remarKS

RESERVER TANK

CAP

1

1

COOLANT LEVEL SWITCH 1

HEX HEAD BOLT .............................................4 ............. DCA300SSC

HEX HEAD BOLT .............................................4 ............. DCA300SSCU

BUSHING

HOSE JOINT

HOSE (L=250)

JOINT

HOSE (L=325)

1

1

8

1

2

1

1

1

1

1

HOSE (L=1100)

HOSE BAND

HOSE

HOSE BAND

HOSE

HOSE

HOSE

1

1

HOSE BAND ....................................................2 ............. DCA300SSC

HOSE BAND ....................................................2 ............. DCA300SSCU

CLAMPER ROD ...............................................1 ............. DCA300SSC

CLAMPER ROD ...............................................1 ............. DCA300SSCU

HEX HEAD BOLT

1

2

1

1 HEX HEAD BOLT

CLAMPER ROD

HEX HEAD BOLT

OIL PRESSURE UNIT

ADAPTER

1

1

PACKING .........................................................1 ............. DCA300SSC

PACKING .........................................................1 ............. DCA300SSCU

WATER TEMPERATURE UNIT ........................1 ............. DCA300SSC

WATER TEMPERATURE UNIT ........................1 ............. DCA300SSCU

ADAPTER

PACKING .........................................................1 ............. REPLACES P/N 0602021109

WATER TEMPERATURE SWITCH 1

1 PICK- UP TACHOMETER

ALTERNATOR

STARTER

WATER PUMP

THERMOSTAT W/O

GASKET, THERMOSTAT

SENSOR, OIL PRESSURE

1

1

1

1

1

1


engine Operating paneL assy.


engine Operating paneL assy.

2

3

1

2

4

5

no.

1

part no. part name QTY. remarKS

C2351101903 OPERATING PANEL ............................................1 ...........DCA300SSC

M5351100003

0017106020

0017106016

0207006000

0602101000

0021008080

5A 0030004000

5B 0040008000

5C 0041608000

6

7

8

9

0601830710

0601831557

0602120095

0602122093

10 0601842450

11 0602123092

12 0602121081

13 0602125091

14 0602103090

14A 0601810244

15 M5483000003 SET FRAME 1

HEX HEAD BOLT .................................................2 ...........DCA300SSC

16 0017110030

16 0016910030

17 0017110030

17A 0030010000

17B 0040010000

17C 0041610000

OPERATING PANEL ............................................1 ...........DCA300SSCU

HEX HEAD BOLT .................................................8 ...........DCA300SSC

HEX HEAD BOLT .................................................8 ...........DCA300SSCU

HEX NUT

BATTERY SWITCH

MACHINE SCREW

HEX NUT

WASHER, LOCK

WASHER, FLAT

ENGINE SPEED SWITCH

EMERGENCY STOP BUTTON

TACHOMETER

OIL PRESSURE GAUGE

VOLTAGE DIVIDER

WATER TEMPERATURE GAUGE

CHARGING AMMETER

FUEL GAUGE

ALARM LAMP

BULB, DC28V

HEX HEAD BOLT .................................................2 ...........DCA300SSCU

HEX HEAD BOLT

HEX NUT

WASHER, LOCK

WASHER, FLAT

3

6

3

3

5

5

1

1

1

1

1

1

1

1

2

2

2

2

4

1


OUtpUt terMinaL assy.


2

3

1

2

5

6

3

4

7

7


1 C2231700403

M5230700003

8

C0277500004

M9220100914

0801830904

9220101004

0039320000

0040020000

0041420000

3501860604

M5233200004

0019110050

8A 0042310000

8B 0042410000

9 0601808803

10 0601808804

11 C3261600704

11 M4260600104

11-1 0221200150

12 0019206020

13 0601814013

14 0601811034

15 0025304015

15 0025304016

15A 0207004000

16 C2234500104

16 M4236400204

17 0019206020

17 0016906016

18 0601815194

19 0025304015

19 7538070

20 0601850275

21 0601851780

21A 0601851780

22 C2237102303

22 M5236100003

23 0019112045

24 0042412000

25 0605015604

25 M9310200004

26 0205012000

27 0845043704

27 M9210000204

28 C2237101204

28 M5236100204



SET BOARD, OUTPUT TERMINAL ............1 ................DCA300SSC

SET BOARD, OUTPUT TERMINAL ............1 ................DCA300SSCU

OUTPUT TERMINAL ...................................8 ................DCA300SSC

OUTPUT TERMINAL ...................................8 ................DCA300SSCU

HEX HEAD BOLT ........................................8 ................DCA300SSC

HEX HEAD BOLT ........................................8 ................DCA300SSCU

HEX NUT

WASHER, LOCK

WASHER, FLAT

16

24

32

TERMINAL PLATE ......................................3 ................DCA300SSC

TERMINAL PLATE ......................................3 ................DCA300SSCU

HEX HEAD BOLT 5

5 WASHER, LOCK

WASHER, FLAT

CIRCUIT BREAKER, 1P 20A

CIRCUIT BREAKER, 2P 50A

5

2

3

BRACKET, CIRCUIT BREAKER .................1 ................DCA300SSC

BRACKET, CIRCUIT BREAKER .................1 ................DCA300SSCU

RUBBER CUSHION

HEX HEAD BOLT

RECEPTACLE

RECEPTACLE, CS6369

1

2

2

3

MACHINE SCREW ....................................10 ...............DCA300SSC

MACHINE SCREW ....................................10 ...............DCA300SSCU

HEX NUT 10

COVER ........................................................1 ................DCA300SSC

COVER ........................................................1 ................DCA300SSCU



TERMINAL BOARD 1

MACHINE SCREW .....................................2 ................DCA300SSC

MACHINE SCREW .....................................2 ................DCA300SSCU

GROMMET 1

GROMMET ..................................................2 ................DCA300SSC

BLIND PLUG ...............................................1 ................DCA300SSCU

COVER, OUTPUT TERMINAL ....................1 ................DCA300SSC

COVER, OUTPUT TERMINAL ....................1 ................DCA300SSCU

HEX HEAD BOLT

WASHER, FLAT

2

4

STAY RUBBER ............................................2 ................DCA300SSC

STAY RUBBER ............................................2 ................DCA300SSCU

HEX NUT 2

SPRING .......................................................2 ................DCA300SSC

SPRING .......................................................2 ................DCA300SSCU

COVER ........................................................1 ................DCA300SSC

COVER ........................................................1 ................DCA300SSCU





29 0017108020

29 0016908020

30 C2237102403

30 M5236100104

31 0019210030

31 014210040

32 0845054204

32 M9116000004

33 0805015604

33 M9310200004

34 C2237101504

34 M4236100604

35 C2237500104

35 M4236400304

36 0017106020

36 0016906016

37 7538070





COVER, OUTPUT TERMINAL ....................1 ................DCA300SSC

COVER, OUTPUT TERMINAL ....................1 ................DCA300SSCU



COLLAR ......................................................2 ................DCA300SSC

COLLAR ......................................................2 ................DCA300SSCU

STAY RUBBER ............................................1 ................DCA300SSC

STAY RUBBER ............................................1 ................DCA300SSCU

COVER ........................................................1 ................DCA300SSC

COVER ........................................................1 ................DCA300SSCU

BRACKET ...................................................1 ................DCA300SSC

BRACKET ...................................................1 ................DCA300SSCU



MACHINE SCREW .....................................4 ................DCA300SSCU


battery assy. (Dca300ssc)


8

9

6

7

4

5

2

3


1 0165511551

part name

BATTERY

C9109100604 BATTERY SHEET

3972250004

0805002904

0037808000

0040008000

BATTERY BAND

BATTERY BOLT

WING NUT

WASHER, LOCK

0041608000 WASHER, FLAT

C2346600404 BATTERY CABLE

C2346600304 BATTERY CABLE

10 C2347600704 BATTERY CABLE

11 C2346600504 BATTERY CABLE

12 C2346200004 EARTH CABLE

13 0347010030

14 0208110000

15

16

17

18

19

20

0845040414

0845041304

0017116030

0040516000

0017112025

0040512000

HEX HEAD BOLT

HEX NUT

TERMINAL CAP (+)

TERMINAL CAP (-)

HEX HEAD BOLT

TOOTHED WASHER

HEX HEAD BOLT

TOOTHED WASHER

battery assy. (Dca300ssc)

4

2

2

4

1

1

1

1

1

1

2

1

1

2

2

2

2

QTY. remarKS

2

2

1


battery assy. (Dca300sscU)


8

9

6

7

4

5

2

3


1 0602220196

part name

BATTERY

M9310500404 BATTERY SHEET

10

11

12

13

M9104000004 BATTERY BAND

0602220921 BATTERY BOLT SET

M5346900404 BATTERY CABLE




M5346200104 EARTH CABLE

0017116030

0040516000

0017112025

0040512000

HEX HEAD BOLT

TOOTHED WASHER

HEX HEAD BOLT

TOOTHED WASHER

battery assy. (Dca300sscU)

1

1

1

2

1

1

1

1

2

1

QTY. remarKS

2

2

1


MUffLer assy.


3

4

1

2


1 C2331100002

M5330100102

0019210025

M5333000003

0602325066

C1334200304 5

5

6

M4333200004

0010312055

6A 0030312000

7

7

6B 0042512000

6C 0041612000

8

C2331300004

M5331300004

0017108020

MUffLer assy.


MUFFLER ...................................................1 ................DCA300SSC

MUFFLER ...................................................1 ................DCA300SSCU

HEX HEAD BOLT

EXHAUST PIPE

BEND BOLT CLAMP

4

1

1

GASKET ......................................................1 ................DCA300SSC

GASKET ......................................................1 ................DCA300SSCU

HEX HEAD BOLT 4

HEX NUT .....................................................4 ................DCA300SSC

WASHER, LOCK .........................................4 ................DCA300SSC

WASHER, FLAT ..........................................8 ................DCA300SSC

COVER ........................................................2 ................DCA300SSC

COVER ........................................................2 ................DCA300SSCU

HEX HEAD BOLT 4


fUeL tank assy. (Dca300ssc)


1-4 0605515079

2

5

6

3

4

7

8


1 C2363000303

1-1 0810105004

1-2 0810105400

1-3 0264100525

9

0605503023

0802120604

0605501093

0605516090

0022905015

8195523104

0805003414

0017108020

10 0207308000

11 0222100300

12 0130206000

13 0134306170

14 0603325026

15 0132006000

16 C1367700304

17 0019208020

18 0845039604

19 0191503400

20 0191503700

21 0605515073

part name

FUEL TANK

CAP, FUEL TANK

FUEL FILTER

HOSE, FUEL GAUGE

HOSE BAND

FUEL SENSOR

PACKING

UNIT, FUEL

PACKING

MACHINE SCREW

TANK BAND

PAD, TANK BAND

HEX HEAD BOLT

SUPER LOCK NUT

TANK SHEET

STREET ELBOW, 1/2"

DRAIN PIPE

VALVE

PLUG, 1/2"

LOCK PLATE

HEX HEAD BOLT

RUBBER SEAL

SUCTION HOSE

RETURN HOSE

HOSE BAND

fUeL tank assy. (Dca300ssc)

2

6

4

4

5

2

1

1

1

1

1

2

QTY.

1

1

1

1

1

1

2

1

4

1

1

1

1 remarKS


fUeL tank assy. (Dca300sscU)


4

5

2

3

8

9

6

7


1 M5363000202

1-1 0605505070

0605501069

0605516090

0027104016

M5364200004

M9310500104

0016908020

0207308000

0222100300

10 M9200000003

11 M9200200004

12 0150000018

13 0016908020

14 M1363400104

15 0605515198

16 0602042682

17 0602042683

18 0191503400

19 0191503700

20 0605515198

fUeL tank assy. (Dca300sscU)

part name

FUEL TANK

CAP, FUEL TANK

FUEL SENSOR UNIT

GASKET

MACHINE SCREW

TANK BAND

SUPPORTER SHEET

HEX HEAD BOLT

SUPER LOCK NUT

RUBBER TANK SHEET

DRAIN JOINT

DRAIN BOLT

O-RING

HEX HEAD BOLT

DRAIN HOSE

HOSE BAND

CONNECTION

CONNECTION

HOSE, SUCTION

HOSE, RETURN

HOSE BAND

2

1

1

1

6

1

2

2

2

4

1

5

QTY.

1

1

1

1

1

2

1

1

4 remarKS


encLOsUre assy.



1

1

2

C2413003202

M5413000004

C3414100104

2A M1413400004

3

3

C2414100004

M5413100204

4 0019208020

4A 0019208020

5

5

C2414600304

M5413600104

5A C2494000304

5A M5493000004

6

6

0017108020

0016908020

7 M5423000002

7A M5493100003

8 M5423000102

8A M5493100003

9 0017108020

10 0019210025

11 C2424200003

11A M5424200203

12 C2424201504

12 M5424200103

12A C2494101104

12A M5494101604

13 0019208020

14 0845042703

15 0019208020

16 M5433000002

encLOsUre assy.


BASE ...........................................................1 ................DCA300SSC

BASE ...........................................................1 ................DCA300SSCU

FLOOR PANEL ............................................1 ................DCA300SSC

FLOOR PANEL ............................................1 ................DCA300SSCU

FLOOR PANEL ............................................1 ................DCA300SSC

FLOOR PANEL ............................................1 ................DCA300SSCU

HEX HEAD BOLT .......................................14 ...............DCA300SSC

HEX HEAD BOLT .......................................12 ...............DCA300SSCU

DUCT ..........................................................1 ................DCA300SSC

DUCT ..........................................................1 ................DCA300SSCU

ACOUSTIC SHEET .....................................1 ................DCA300SSC

ACOUSTIC SHEET .....................................1 ................DCA300SSCU



FRONT FRAME

ACOUSTIC SHEET

FRONT FRAME

ACOUSTIC SHEET

HEX HEAD BOLT

1

1

1

1

HEX HEAD BOLT

10

8

COVER, FRONT FRAME ............................1 ................DCA300SSC

COVER, FRONT FRAME ............................1 ................DCA300SSCU

COVER, FRONT FRAME ............................1 ................DCA300SSC

COVER, FRONT FRAME ............................1 ................DCA300SSCU



HEX HEAD BOLT 23

FILLER BRACKET ......................................1 ................DCA300SSC


CENTER FRAME 1


encLOsUre assy. (cOntinUeD)



17 0010114050

17A 0030014000

17B 0040014000

17C 0041214000

18 0010114040

18A 0030014000

18B 0040014000

18C 0041214000

19 C2367700404

19 M5366700204

20 0019208020

21 M5443000002

21A C2494300204

21A M5493300904

22 0019210025

23 M5443300003

23A M5493300004

24 M5443300104

24A M5493300104

25 0016908020

26 0019208020

27 M5453000003

28 M5453000103

29 8225147004

29 M5443600004

30 0207306000

30A 0041206000

31 B9114000102

31 M9113000202

32 0021806016

32A 0030006000


part name

HEX HEAD BOLT

HEX NUT

WASHER, LOCK

WASHER, FLAT

HEX HEAD BOLT

HEX NUT

WASHER, LOCK

8

8

8

8

QTY.

4

4

4 remarKS

WASHER, FLAT 16

COVER ........................................................1 ................DCA300SSC

COVER ........................................................1 ................DCA300SSCU

HEX HEAD BOLT

REAR FRAME

2

1



HEX HEAD BOLT

COVER, REAR FRAME

ACOUSTIC SHEET

PANEL

ACOUSTIC SHEET

4

1

HEX HEAD BOLT

HEX HEAD BOLT

DOOR, REAR FRAME

DOOR, REAR FRAME

1

12

1

1

14

1

1

WINDOW PLATE .........................................2 ................DCA300SSC

WINDOW PLATE .........................................2 ................DCA300SSCU

SELF- LOCKING U-NUT 12

12 WASHER, FLAT

DOOR HANDLE ..........................................1 ................DCA300SSC

DOOR HANDLE ..........................................1 ................DCA300SSCU

MACHINE SCREW

HEX NUT

4

4





33 C3444700004

33 M9114300004

34 8195146304

34 M9114300104

35 0845050704

35 M9113300004

36 0207006000

37 0805011304

37 M9113400104

38 0805011204

38 M113400204

39 0207006000

40 M9110100204

40A 0845045004

40A M9116100004

41 M9110100304

41A 0845045004

41A M9116100004

42 0019208020

43 0601850097

44 0025408025

45 0845031504

45 M9310000004

46 0600800320

47 0207006000

48 M5463100002

48A M5493500004

49 M3310600004

50 0019208020

51 C2464200502

51 M5463200102

51A C2494500904

51A M5493502004

52 M5423200103

53 0019208020

54 M5453200002

55 0019208065



DOOR ROD .....................................................1..................

DCA300SSC

DOOR ROD .................................................1 ................DCA300SSCU

DOOR ROD .................................................1 ................DCA300SSC

DOOR ROD .................................................1 ................DCA300SSCU

STAY 4

4 STAY

HEX NUT

DCA300SSC

DCA300SSCU

8

STOPPER, DOOR.......................................1 ................DCA300SSC

STOPPER, DOOR.......................................1 ................DCA300SSCU

STOPPER, DOOR.......................................1 ................DCA300SSC

STOPPER, DOOR.......................................1 ................DCA300SSCU

HEX NUT

HINGE

4

2

WASHER .....................................................2 ................DCA300SSC

WASHER .....................................................2 ................DCA300SSCU

HINGE 2

WASHER .....................................................2 ................DCA300SSC

WASHER .....................................................2 ................DCA300SSCU

HEX HEAD BOLT

STOPPER

MACHINE SCREW

CAP

CAP

6

2

MANUAL PAK

HEX NUT

ROOF PANEL

ACOUSTIC SHEET

COVER

HEX HEAD BOLT

4

1

2

4

4

1

1

1

4

ROOF PANEL ..............................................1 ................DCA300SSC

ROOF PANEL ..............................................1 ................DCA300SSCU



COVER, FRONT FRAME

HEX HEAD BOLT

SPLASHER PANEL

HEX HEAD BOLT

1

41

1

6





56 M5453000203

56A M5493400004

57 M5453000303

57A M5493400104

58 M5453000803

58A M5493409304

59 M5453000903

59A M5493409404

60 M5453300004

60A M5493400204

61 M5453300104

61A M5493400304

62 M5453300904

62A M5493409504

63 M5453300204

63A M5493400404

64 0207008000

65

65

B9114000002

M9113000002

66

66

0825007362

M9113000102

67 0021806016

67A 0030006000

68 0845046904

68 M9110100804

68A 0845045004

68A M9116100004

69 084504700

69 M9110100904

69A 0845045004

69A M9116100004

70 0019208020

71 0601850097

72 0025408025

73 0845031504

73 M9310000004

74 M5463500004

75 C2464500304

75 M5463500104

76 0019208020

77 0019116025

78 0042416000


part name

SIDE PANEL

ACOUSTIC SHEET

SIDE PANEL

ACOUSTIC SHEET

SIDE PANEL

ACOUSTIC SHEET

SIDE PANEL

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

HEX NUT

QTY.

1

1

2

2

35

1

1

1

1

1

1

1

1

1

1

1

1 remarKS

DOOR HANDLE ................................................4..................

DOOR HANDLE ................................................4..................

DOOR HANDLE .............................................3 .................

DOOR HANDLE .............................................3 .................

MACHINE SCREW

HEX NUT

DCA300SSC

DCA300SSCU

DCA300SSC

DCA300SSCU

28

16

HINGE .........................................................5 ................DCA300SSC

HINGE .........................................................5 ................DCA300SSCU

WASHER .....................................................5 ................DCA300SSC

WASHER .....................................................5 ................DCA300SSCU

HINGE .........................................................6 ................DCA300SSC

HINGE .........................................................6 ................DCA300SSCU

WASHER .....................................................6 ................DCA300SSC

WASHER .....................................................6 ................DCA300SSCU

HEX HEAD BOLT

STOPPER

25

8

MACHINE SCREW 8

CAP ............................................................11 ...............DCA300SSC

CAP ............................................................11 ...............DCA300SSCU

GUTTER ......................................................2

GUTTER ......................................................2 ................DCA300SSC

GUTTER ......................................................2 ................DCA300SSCU

HEX HEAD BOLT 4


WASHER, FLAT ..........................................1 ................DCA300SSCU


rUbber seaLs assy.



1

2

3

4

5

0229201400

0228901015

0228901250

0228901310

0228900650

7

8

5

6

0228900650

0228900650

0228900710

0229201300

9 0221200705

10 0228801210

11 0228100510

12 0228100120

13 0229200470

14 0229201130

rUbber seaLs assy.

part name QTY.

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

3

3

4

4

SEAL RUBBER ..............................................4 .................

remarKS

DCA300SSC

DCA300SSCU SEAL RUBBER ..............................................4 .................

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

1

1

1

2

2

4

4

2

1


naMepLate anD DecaLs assy. (Dca300ssc)



1-1 C3550000703

1-2 C9522100003

2-1 0800520100

2-2 0800520904

2-3 0800520814

2-4 0840624504

2-5 0840624604

2-6 0840624704

2-7 0840624804

2-8 B9531100604

2-9 C0551000903

2-10 C2551000004

2-11 M5560100903

2-12 C9502400004

2-13 C9520027704

2-14 C9520028604

2-15 C9520028704

2-16 C9520028804

2-17 C9521007504

2-18 Z0110001504

3-1 6360610304

3-2 6360620204

3-3 B9504000404

3-4 B9504100104

4-1 C0551000504

4-2 C3550000404

4-3 M5550000503

5-1 0840614104

5-2 0840619904

5-3 9039209064

5-4 B9511100304

5-5 B9511100404

5-6 B9531100504

5-7 C0551000404

5-8 C1551000803

naMepLate anD DecaLs assy. (Dca300ssc)


DECAL : HANDLING PROCEDURES .........................1 ................. C35000070

DECAL : CAUTION ......................................................2 ................. C92210000

CONTROL BOX GROUP

PLATE : ON - OFF........................................................1 ................. AT-202

PLATE : AMMETER CHANGE- OVER SWITCH..........1 ................. N-2438

PLATE : VOLTMETER CHANGE- OVER SWITCH ......1 ................. N-2439

DECAL : CIRCUIT BREAKER .....................................1 ................. S-3031

DECAL : PANEL LIGHT SWITCH ................................1 ................. S-3032

DECAL : PILOT LAMP .................................................1 ................. S-3033

DECAL : VOLTAGE REGULATOR ................................1 ................. S-3034

DECAL : WARNING ELECTRIC SHOCK HAZARD .....1 ................. B93110060

DECAL : SETTING FOR OUTPUT VOLTAGE ..............1 ................. C05100090

DECAL : SAFETY INSTRUCTIONS ............................1 ................. C25100000

DECAL : WHISPERWATT 300 .....................................1 ................. M56010090A

DECAL : HIGH IDLE SPEED .......................................1 ................. C90240000

DECAL : DIAGNOSTIC BUTTON ................................1 ................. C92002770

DECAL : WARNING DIAGNOSTIC LAMP ...................1 ................. C92002860

DECAL : SHUTDOWN DIAGNOSTIC LAMP ...............1 ................. C92002870

DECAL : LOW IDLE SPEED / DIAG. CODE SW. .........1 ................. C92002880

DECAL : DIAGNOSTIC SWITCH .................................1 ................. C92100750

DECAL : RESET ..........................................................1 ................. Z01000150

ENGINE & RADIATOR GROUP

DECAL : WATER ..........................................................1 ................. S-1880

DECAL : OIL DRAIN PLUG .........................................1 ................. S-1885

DECAL : MOVING PARTS ...........................................2 ................. B90400040

DECAL : WARNING HOT COOLANT ..........................1 ................. B90410010

ENGINE OPERATING PANEL GROUP

DECAL : BATTERY SWITCH .......................................1 ................. C05100050

DECAL : ALARM LAMP ...............................................1 ................. C35000040

DECAL : OPERATING PANEL .....................................1 ................. M55000050

OUTPUT TERMINAL GROUP

DECAL : GROUND ......................................................1 ................. S-2635

DECAL : DANGER HIGH VOLTAGE ............................1 ................. S-2731

DECAL : START CONTACT .........................................1 ................. S-4468

DECAL : WARNING .....................................................1 ................. B91110030



DECAL : 3- PHASE OUTPUT TERMINAL ...................1 ................. C05100040

DECAL : RECEPTACLE & CIRCUIT BREAKER ..........1 ................. C15100080


naMepLate anD DecaLs assy. (cOntinUeD Dca300ssc)


naMepLate anD DecaLs assy. (cOntinUeD Dca300ssc)


6-1 0800689404

6-2 0800689504

6-3 C9505300004


BATTERY GROUP

DECAL : + ............................................................... 1 ...................... S-2090

DECAL : - ................................................................ 1 ...................... S-2091

DECAL : CAUTION ................................................. 1 ...................... C90530000

7-1 A9504000014

7-2 B9504200004

8-1 1320620904

8-2 6360620004

8-3 B9504500004

9-1 1320610603

9-2 1320621504

9-3 0840625902

9-4 B9504000304

9-5 B9531100604

9-6 0600500090

9-6A 0021106016

9-7 M5560101503

9-8 M5560101303

9-9 M5560101103

9-10 M5560101004

9-11 M5560101403

9-12 M5560101203

9-13 C9504000304

9-14 M9504200004

MUFFLER GROUP

DECAL : DANGER ........................................................................... A90400001

DECAL : WARNING ENGINE EXHAUST ................ 1 ...................... B90420000

FUEL TANK GROUP

DECAL : DIESEL FUEL .......................................... 1 ...................... S-1756

DECAL : FUEL DRAIN PLUG ................................. 1 ...................... S-1883

DECAL : WARNING DIESEL FUEL ........................ 1 ...................... B90450000

ENCLOSURE GROUP

DECAL : WATER - OIL ........................................... 1 ...................... S-1760

DECAL : SUPPORT HOOK .................................... 2 ...................... S-2257

DECAL : MQ ........................................................... 1 ...................... S-3057

DECAL : CAUTION HOT PARTS ............................ 1 ...................... B90400030

DECAL : WARNING ELECTRIC SHOCK HAZARD 1 ...................... B93110060

EMBLEM

MACHINE SCREW

STRIPE

STRIPE

STRIPE

STRIPE

STRIPE

STRIPE

1

1

1

4

1

1

2

4

DECAL : CAUTION ................................................. 1 ...................... C90400030

DECAL : WARNING START FIRES ........................ 1 ...................... M90420000


naMepLate anD DecaLs assy. (Dca300sscU)



1-1 M5550000303

1-2 M9520100603

naMepLate anD DecaLs assy. (Dca300sscU)


DECAL : HANDLING PROCEDURES .........................1 ................. M55000030

DECAL : CAUTION ......................................................2 ................. M92010060

2-1 M5560100903

2-2 M9520000104

2-3 M9520000204

2-4 M9520000904

2-5 M9520001104

2-6 M9520001504

2-7 M9520001804

2-8 M9520001904

2-9 M9520001904

2-10 M9522000404

2-11 M9520001304

2-12 M9520001404

2-13 M9520100004

2-14 M9520100304

2-15 M9520200303

2-16 M9522000504

2-17 M9522000704

3-2 M9500000004

3-1 M9500100004

3-3 M9503000004

3-4 M9510100004

3-5 M9503100004

3-6 M9510100004

4-1 M5550000103

4-3 M5550000503

4-1 M9520001604

5-1 M4550000103

5-2 M9520000004

5-3 M9520000504

5-4 M9520000704

5-5 M9520100404

5-6 M9520100503

CONTROL BOX GROUP

DECAL : WHISPERWATT 300 .....................................1 ................. M56010090A

PLATE : AMMETER CHANGE-OVER SWITCH...........1 ................. M92000010

PLATE : VOLTMETER CHANGE-OVER SWITCH .......1 ................. M92000020

DECAL : DIAGNOSTIC SWITCH .................................1 ................. M92000090

DECAL : DIAGNOSTIC BUTTON ................................1 ................. M92000110

DECAL : RESET ..........................................................1 ................. M92000150

DECAL : WARNING DIAGNOSTIC LAMP ...................1 ................. M92000180

DECAL : SHUTDOWN DIAGNOSTIC LAMP ...............1 ................. M92000190

DECAL : LOW IDLE SPEED/DIAG. CODE SWITCH ...1 ................. M92000200

DECAL : HIGH IDLE SPEED .......................................1 ................. M92200040

DECAL : VOLTAGE REGULATOR ................................1 ................. M92000130

DECAL : PILOT LAMP .................................................1 ................. M92000140

DECAL : WARNING ELECTRIC SHOCK HAZ. ............1 ................. M92010000

DECAL : GENERAL CAUTION ....................................1 ................. M92010030

DECAL : SETTING FOR OUTPUT VOLTAGE ..............1 ................. M92020030

DECAL : CIRCUIT BREAKER. .....................................1 ................. M92200050

DECAL : PANEL LIGHT SWITCH ................................1 ................. M92200070

ENGINE & RADIATOR GROUP

DECAL : OIL DRAIN PLUG .........................................1 ................. M90000000

DECAL : WATER ..........................................................1 ................. M90010000

DECAL : MOVING PARTS ...........................................2 ................. M90300000

DECAL : WATER OIL ...................................................1 ................. M91010000

DECAL : WARNING RADIATOR CAP ..........................1 ................. M90310000

DECAL : HIGH TEMP ..................................................1 ................. M91010000

ENGINE OPERATING PANEL GROUP

DECAL : ALARM LAMP ...............................................1 ................. M55000010

DECAL : OPERATING PANEL .....................................1 ................. M55000050

DECAL : BATTERY SWITCH .......................................1 ................. M92000160

OUTPUT TERMINAL GROUP

DECAL : AUXILIARY OUTPUTS ..................................1 ................. M45000010

DECAL : GROUNDING ................................................1 ................. M92000000

DECAL : START CONTACT .........................................1 ................. M92000050

DECAL : 3-PHASE OUTPUT TERMINAL ....................1 ................. M92000070

DECAL : DANGER HIGH VOLTAGE ............................1 ................. M92010040

DECAL : WARNING ELECTRIC SHOCK HAZARD .....1 ................. M92010050


naMepLate anD DecaLs assy. (cOntinUeD Dca300sscU)


naMepLate anD DecaLs assy. (cOntinUeD Dca300sscU)


6-1 M9500300004

6-2 M9500300104

6-3 M9510100403


BATTERY GROUP

DECAL : - ................................................................ 1 ...................... M90030000

DECAL : + ............................................................... 1 ...................... M90030010

DECAL : WARNING BATTERY CONNECT ............ 1 ...................... M91010040A

7-1 M9503200004

7-2 M9503200104

8-1 M9500500004

8-2 M9500500104

9-1 M9510200002

9-2 0600500090

9-2A 0021106016

9-3 M5560101004

9-4 M5560101103

9-5 M5560101203

9-6 M5560101303

9-7 M5560101403

9-8 M5561100403

9-9 M5550000004

9-10 M9504200004

9-11 M9510000104

9-12 M9512000004

MUFFLER GROUP

DECAL : WARNING ENGINE EXHAUST ......................................... M90320000

DECAL : DANGER EXHAUST GAS INDOOR ........ 1 ...................... M90320010

FUEL TANK GROUP

DECAL : DIESEL FUEL .......................................... 1 ...................... M95005000

DECAL : FUEL DRAIN PLUG ................................. 1 ...................... M950050010

ENCLOSURE GROUP

DECAL : MQ ........................................................... 1 ...................... M91020000

EMBLEM

MACHINE SCREW

STRIPE

STRIPE

STRIPE

STRIPE

STRIPE

STRIPE

2

4

1

1

1

4

1

1

DECAL : CAUTION LIFTING CAP .......................... 1 ...................... M55000000

DECAL : WARNING START FIRES ........................ 1 ...................... M90420000

DECAL : DOCUMENT BOX LOCATED ................... 1 ...................... M91000010

DECAL : SUPPORT HOOK .................................... 2 ...................... M91200000


terMs anD cOnDitiOns Of saLe — parts

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:

1.

2.

3.

4.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

To obtain a Return Material Authorization, a list must be provided to Multiquip

Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions must match the current parts price list.

b. The list must be typed or computer generated.

c. d.

The list must state the reason(s) for the return.

The list must reference the sales order(s) or invoice (s) under which the items were originally purchased.

e. The list must include the name and phone number of the person requesting the RMA.

A copy of the Return Material Authorization must accompany the return shipment.

Freight is at the sender’s expense. All parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5.

6.

7.

8.

9.

10.

11. d. e. f. g. h.

Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

The following items are not returnable: a. b.

Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.)

Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer net price of less than

$5.00.

Special order items.

Electrical components.

Paint, chemicals, and lubricants.

Decals and paper products.

Items purchased in kits.

The sender will be notified of any material received that is not acceptable.

Such material will be held for five 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 at dealer net price at time of the original purchase, less a 15% restocking charge.

In cases where an item is accepted, for 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 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 after that date will be billed at the revised price.

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 EXPEDITING 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 for 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 102 — DCa300SSC / DCa300SSCU gen. • operation anD partS manUal — rev. #1 (08/10/11)

nOtes


OperatiOn anD parts ManUaL

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Office

18910 Wilmington Ave.

Carson, CA 90746

Contact: [email protected]

Service Department

800-421-1244

310-537-3700

Technical Assistance

800-478-1244

Tel. (800) 421-1244

Fax (800) 537-3927

Fax: 310-537-4259

Fax: 310-943-2238 mexico

MQ Cipsa

Carr. Fed. Mexico-Puebla KM 126.5

Momoxpan, Cholula, Puebla 72760 Mexico


Tel: (52) 222-225-9900

Fax: (52) 222-285-0420

MQ Parts Department

800-427-1244

310-537-3700

Warranty Department

800-421-1244

310-537-3700

Fax: 800-672-7877

Fax: 310-637-3284

Fax: 310-943-2249

United Kingdom

Multiquip (UK) Limited Head Office

Unit 2, Northpoint Industrial Estate,

Globe Lane,

Dukinfield, Cheshire SK16 4UJ


Tel: 0161 339 2223

Fax: 0161 339 3226

Canada

Multiquip

4110 Industriel Boul.

Laval, Quebec, Canada H7L 6V3


Tel: (450) 625-2244

Tel: (877) 963-4411

Fax: (450) 625-8664

© COPYRIGHT 2011, MULTIQUIP INC.

Multiquip Inc and the MQ 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 specifications 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 specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

Manufactured for

Multiquip Inc.

by

DENYO CO., LTD, JAPAN

MQ Power DCA300SSC-SSCU Generator Operation And Parts Manual

OperatiOn anD parts ManUaL

WhisperWatt™ series

60hz generatOr

(cUMMins qsL9-g3 DieseL engine)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

prOpOsitiOn 65 Warning

Diesel engine exhaust and some of

repOrting safety Defects

tabLe Of cOntents component Drawings

parts OrDering prOceDUres

Ordering parts has never been easier!

Choose from three easy options:

Order Parts

When ordering parts, please supply:

SaFetY meSSageS

safety infOrMatiOn

general SaFetY

safety infOrMatiOn

generator SaFetY

engine SaFetY

safety infOrMatiOn

FUel SaFetY

toWing SaFetY

safety infOrMatiOn

eleCtriCal SaFetY

Power Cord/Cable Safety

safety infOrMatiOn

Grounding Safety

BatterY SaFetY

safety infOrMatiOn environmental SaFetY

specificatiOns

DiMensiOns

instaLLatiOn

oUtDoor inStallation

inDoor inStallation

moUnting

instaLLatiOn generator groUnDing

generator

engine operating panel

generator Control panel

oUtpUt terminal panel

generaL infOrMatiOn open Delta exCitation SYStem

engine

eleCtriC governor SYStem

extenSion CaBleS

MajOr cOMpOnents

generatOr cOntrOL paneL

generatOr cOntrOL paneL

engine Operating paneL

nOtes

OUtpUt terMinaL paneL faMiLiarizatiOn oUtpUt terminal panel

oUtpUt terminal Familiarization

OUtpUt terMinaL paneL faMiLiarizatiOn

120 vaC gFCi receptacles

twist lock Dual voltage 120/240 vaC receptacles

OUtpUt terMinaL paneL faMiLiarizatiOn

Connecting loads

over Current relay

Single pHaSe loaD

LOaD appLicatiOn tHree pHaSe loaD

generator oUtpUt voltageS

voltage Change-over Board

generatOr OUtpUts maximum amps

generatOr OUtpUts/gaUge reaDing

HoW to reaD tHe aC ammeter anD aC voltage gaUgeS

aC ammeter gauge reading

aC voltmeter gauge reading

OUtpUt terMinaL paneL cOnnectiOns

UvWo terminal oUtpUt voltageS

3Ø-240v UvWo terminal output voltages

1Ø-240v UvWo terminal output voltages

1Ø-120v UvWo terminal output voltages

OUtpUt terMinaL paneL cOnnectiOns

3Ø-480v UvWo terminal output voltages

1Ø-480v UvWo terminal output voltages

1Ø-277v UvWo terminal output voltages

CirCUit BreaKerS

lUBriCation oil

inspectiOn/setUp