Cummins QSL 9 Wiring Diagram PDF

OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA300SSC
60HZ GENERATOR
(CUMMINS QSL9-G3 DIESEL ENGINE)
PARTS LIST NO. C2870300204
Revision #0 (06/25/09)
To find the latest revision of this

publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)

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 GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 3

TABLE OF CONTENTS
DCA300SSC Component Drawings
60 Hz Generator Generator Assembly ......................................... 56-59
Proposition 65 warning ............................................ 2 Control Box Assembly. ...................................... 60-63
Reporting Safety Defects......................................... 3 Engine and Radiator Assembly......................... 64-67
Table of Contents..................................................... 4 Engine Operating Panel Assembly.................... 68-69
Parts Ordering Procedures ...................................... 5 Output Terminal Assembly ............................... 70-71
Safety Information .............................................. 6-11 Battery Assembly.............................................. 72-73
Specifications ........................................................ 12 Muffler Assembly............................................... 74-75
Dimensions ............................................................ 13 Fuel Tank Assembly. ......................................... 76-77
Installation ........................................................ 14-15 Enclosure Assembly ......................................... 78-83
General Information ............................................... 16 Rubber Seals Assembly ................................... 84-85
Major Components ................................................ 17 Nameplate and Decals Assembly..................... 86-89
Generator Control Panel ................................... 18-19
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24 Terms and Conditions of Sale — Parts ................. 90
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

PARTS ORDERING PROCEDURES
www.mqpower.com Ordering parts has never been easier!
Choose from three easy options: Effective:
January 1st, 2006
Best Deal! Order via Internet (Dealers Only): If you have an MQ Account, to obtain a Username
Order parts on-line using Multiquip’s SmartEquip website! and Password, E-mail us at: parts@multiquip.
■ View Parts Diagrams com.
■ Order Parts To obtain an MQ Account, contact your
■ Print Specification Information District Sales Manager for more information.
Goto www.multiquip.com and click on Use the internet and qualify for a 5% Discount
Order Parts to log in and save! on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Order via Fax (Dealers Only): Fax your order in and qualify for a 2% Discount
All customers are welcome to order parts via Fax. on Standard orders for all orders which include
Domestic (US) Customers dial: complete part numbers.*
1-800-6-PARTS-7 (800-672-7877) 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 International Customers should contact
parts or call 800-427-1244 for help in their local Multiquip Representatives for
locating a dealer near you. Parts Ordering information.
When ordering parts, please supply:

❒ Dealer Account Number ❒ Specify Preferred Method of Shipment:
❒ Dealer Name and Address ✓ UPS/Fed Ex ✓ DHL
❒ Shipping Address (if different than billing address) ■ Priority One ✓ Truck
■ Ground
❒ Return Fax Number
■ Next Day
❒ Applicable Model Number ■ Second/Third Day
❒ 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!

SAFETY INFORMATION
Do not operate or service the equipment before reading the Potential hazards associated with the operation of this
entire manual. Safety precautions should be followed at all equipment will be referenced with hazard symbols which
times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with
understand the safety messages and operating instructions safety messages.
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 specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
COULD result in DEATH or SERIOUS INJURY.
CAUTION
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.

SAFETY INFORMATION
GENERAL SAFETY  NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
CAUTION to the equipment and/or injury to user may result.
 NEVER operate this equipment without proper protective  ALWAYS know the location of the nearest
clothing, shatterproof glasses, respiratory protection, fire extinguisher.
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.  ALWAYS know the location of the nearest
first 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
 NEVER operate this equipment when not fire department. This information will be invaluable in
feeling well due to fatigue, illness or when the case of an emergency.
under medication.
 NEVER operate this equipment under the influence of
drugs or alcohol.
GENERATOR SAFETY
DANGER
 NEVER operate the equipment in an explosive
 ALWAYS check the equipment for loosened threads or atmosphere or near combustible materials. An
bolts before starting. explosion or fire could result causing severe
bodily harm or even death.
 DO NOT use the equipment for any purpose other than
its intended purposes or applications. WARNING
NOTICE  NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
 This equipment should only be operated by trained and Disconnection of these devices can cause severe injury,
qualified personnel 18 years of age and older. bodily harm or even death. Disconnection of any of these
 Whenever necessary, replace nameplate, operation and devices will void all warranties.
safety decals when they become difficult read. CAUTION
 Manufacturer does not assume responsibility for any  NEVER lubricate components or attempt service on a
accident due to equipment modifications. Unauthorized running machine.
equipment modification will void all warranties.
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

SAFETY INFORMATION
ENGINE SAFETY NOTICE
DANGER  NEVER run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filter
 The engine fuel exhaust gases contain poisonous carbon
frequently to prevent engine malfunction.
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.  NEVER tamper with the factory settings
of the engine or engine governor. Damage
 The engine of this equipment
to the engine or equipment can result
requires an adequate free
if operating in speed ranges above the
flow of cooling air. NEVER
maximum allowable.
operate this equipment in
any enclosed or narrow area  Wet stacking is a common problem with diesel engines
where free flow of the air is which are operated for extended periods with light or
restricted. If the air flow is no load applied. When a diesel engine operates without
restricted it will cause injury to people and property and sufficient load (less than 40% of the rated output), it will
serious damage to the equipment or engine. not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
WARNING
which can foul the fuel injectors, engine valves and
 DO NOT place hands or fingers inside engine exhaust system, including turbochargers, and reduce
compartment when engine is running. the operating performance.
 NEVER operate the engine with heat shields or In order for a diesel engine to operate at peak efficiency,
guards removed. it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
 Keep fingers, hands hair and clothing away to completely burn all of the fuel.
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
 DO NOT remove the radiator cap while the damage and can be alleviated if additional load is
engine is hot. High pressure boiling water applied to relieve the condition. It can reduce the system
will gush out of the radiator and severely performance and increase maintenance. Applying an
scald any persons in the general area of increasing load over a period of time until the excess
the generator. fuel is burned off and the system capacity is reached
 DO NOT remove the coolant drain plug while the engine usually can repair the condition. This can take several
is hot. Hot coolant will gush out of the coolant tank and hours to burn off the accumulated unburned fuel.
severely scald any persons in the general area of the  State Health Safety Codes and Public Resources
generator. Codes specify that in certain locations, spark arresters
 DO NOT remove the engine oil drain plug while the must be used on internal combustion engines that use
engine is hot. Hot oil will gush out of the oil tank and hydrocarbon fuels. A spark arrester is a device designed
severely scald any persons in the general area of the to prevent accidental discharge of sparks or flames
generator. from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
CAUTION purpose. In order to comply with local laws regarding
 NEVER touch the hot exhaust manifold, spark arresters, consult the engine distributor or the
muffler or cylinder. Allow these parts to cool local Health and Safety Administrator.
before servicing equipment.

SAFETY INFORMATION
FUEL SAFETY  Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
DANGER vehicle weight rating.”
 DO NOT start the engine near spilled fuel or combustible  ALWAYS inspect the hitch and coupling for wear. NEVER
fluids. Diesel fuel is extremely flammable and its vapors tow a trailer with defective hitches, couplings, chains, etc.
can cause an explosion if ignited.
 Check the tire air pressure on both towing vehicle and
 ALWAYS refuel in a well-ventilated area, away from trailer. Trailer tires should be inflated to 50 psi cold.
sparks and open flames. Also check the tire tread wear on both vehicles.
 ALWAYS use extreme caution when working with  ALWAYS make sure the trailer is equipped with a safety
flammable liquids. chain.
 DO NOT fill the fuel tank while the engine is running  ALWAYS properly attach trailer’s safety chains to towing
or hot. vehicle.
 DO NOT overfill tank, since spilled fuel could ignite if it  ALWAYS make sure the vehicle and trailer directional,
comes into contact with hot engine parts or sparks from backup, brake and trailer lights are connected and
the ignition system. working properly.
 Store fuel in appropriate containers, in well-ventilated  DOT Requirements include the following:
areas and away from sparks and flames.
• Connect and test electric brake operation.
 NEVER use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
 DO NOT smoke around or near the wraps.
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a  The maximum speed for highway towing is 55 MPH unless
hot engine. posted otherwise. Recommended off-road towing is not to
exceed 15 MPH or less depending on type of terrain.
TOWING SAFETY
 Avoid sudden stops and starts. This can cause skidding,
CAUTION or jack-knifing. Smooth, gradual starts and stops will
improve towing.
 Check with your local county or state safety
towing regulations, in addition to meeting  Avoid sharp turns to prevent rolling.
Department of Transportation (DOT)  Trailer should be adjusted to a level position at all times
Safety Towing Regulations, before towing when towing.
your generator.
 Raise and lock trailer wheel stand in up position when
 Refer to MQ Power trailer manual for additional safety towing.
information.
 Place chock blocks underneath wheel to prevent rolling
 In order to reduce the possibility of an accident while while parked.
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and  Place support blocks underneath the trailer’s bumper
the towing vehicle are mechanically sound and in good to prevent tipping while parked.
operating condition.
 Use the trailer’s swivel jack to adjust the trailer height to
 ALWAYS shutdown engine before transporting a level position while parked.

SAFETY INFORMATION
ELECTRICAL SAFETY  Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
DANGER may cause electrical shock and damage to the
 DO NOT touch output terminals during generator.
operation. Contact with output terminals NOTICE
during operation can cause electrocution,
electrical shock or burn.  ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
 The electrical voltage required to Chart in this manual.
operate the generator can cause severe
injury or even death through physical contact with live Grounding Safety
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or DANGER
making contact with output terminals.  ALWAYS make sure that electrical circuits are properly
 NEVER insert any objects into the output grounded to a suitable earth ground (ground rod) per
receptacles during operation. This is the National Electrical Code (NEC) and local codes
extremely dangerous. The possibility exists before operating generator. Severe injury or death by
of electrical shock, electrocution or electrocution can result from operating an ungrounded
death. generator.
 Backfeed to a utility system can cause  NEVER use gas piping as an electrical ground.
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.

SAFETY INFORMATION
BATTERY SAFETY ENVIRONMENTAL SAFETY
DANGER NOTICE
 DO NOT drop the battery. There is a possibility that the  Dispose of hazardous waste properly.
battery will explode. Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
 DO NOT expose the battery to open flames,
sparks, cigarettes, etc. The battery contains  DO NOT use food or plastic containers to
combustible gases and liquids. If these dispose of hazardous waste.
gases and liquids come into contact with a
 DO NOT pour waste, oil or fuel directly onto the ground,
flame or spark, an explosion could occur.
down a drain or into any water source.
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.

SPECIFICATIONS
Table 1. Generator Specifications
Model DCA300SSC
Revolving field, self ventilated,
Type
Drip proof, Single bearing
Armature Connection Star with Neutral
Phase 3
Standby Output 330 KVA (264 KW)
Prime Output 300 KVA (240 KW)
Voltage — 1Ø 120,127,139, 240, 254 and 277V
Voltage — 3Ø 208, 220, 240, 416, 440 and 480V
Frequency 60 Hz
Speed 1800 rpm
Power Factor 0.8
Aux. AC Power Single Phase, 60 Hz
Aux. Voltage/Output 4.8 Kw (2.4 kW x 2)
Weight No Fuel 8,644 lbs. (3920 kg)
Weight Fuel 9,769 lbs. (4430 kg)
Table 2. Engine Specifications
Model Cummins QSL9-G3
Type 4 cycle, water-cooled, direct injection, turbocharged, charge air cooled
No. of Cylinders 6 cylinders
Bore x Stroke 4.49 in. x 5.69 in. (114 mm x 145 mm)
Displacement 543 cu. in. (8900 cc)
Rated Output 363 HP at 1800 rpm
Starting Electric
Coolant Capacity 11.3 gal. (43.0 liters)
Lube Oil Capacity 7.0 gal. (26.5 liters)
Fuel Type #2 Diesel Fuel
Fuel Tank Capacity 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
Fuel Consumption
11.1 gal. (41.9 L)/hr at 1/2 load 5.9 gal. (22.4 L)/hr at 1/4 load
Battery 150 Ah x 2 (24V System)

DIMENSIONS
Figure 1. Dimensions
Table 3. Dimensions
Reference
Dimension in. (mm) Reference Letter Dimension in. (mm)
Letter
A 39.76 in. (1,010 mm) F 43.90 in. (1,115 mm)
B 43.90 in. (1,115 mm) G 149.61 in. (3,800 mm)
C 23.03 in. (585 mm.) H 70.87 in. (1,800 mm)
D 25.20 in. (640 mm) I 55.12 in. (1,400 mm)
E 39.76 in. (1,010 mm)

INSTALLATION
Figure 2. Typical Generator Grounding Application

INSTALLATION
OUTDOOR INSTALLATION GENERATOR GROUNDING
Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to
bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH
generator is on secure level ground so that it cannot slide ground.
or shift around. Also install the generator in a manner so
Article 250 (Grounding) of the National Electrical Code
that the exhaust will not be discharged in the direction of
(NEC) provides guide lines for proper grounding and
nearby homes.
specifies that the cable ground shall be connected to the
The installation site must be relatively free from moisture grounding system of the building as close to the point of
and dust. All electrical equipment should be protected from cable entry as practical.
excessive moisture. Failure to do will result in deterioration
NEC articles 250-64(b) and 250-66 set the following
of the insulation and will result in short circuits and
grounding requirements:
grounding.
1. Use one of the following wire types to connect the
Foreign materials such as dust, sand, lint and abrasive
generator to earth ground.
materials have a tendency to cause excessive wear to
engine and alternator parts. a. Copper - 10 AWG (5.3 mm2) or larger.
CAUTION b. Aluminum - 8 AWG (8.4 mm2) or larger.
Pay close attention to ventilation when operating the 2. When grounding the generator (Figure 2) connect the
generator inside tunnels and caves. The engine exhaust ground cable between the lock washer and the nut on
contains noxious elements. Engine exhaust must be the generator and tighten the nut fully. Connect the
routed to a ventilated area. other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
INDOOR INSTALLATION should be buried a minimum of 8 ft. into the ground.
Exhaust gases from diesel engines are extremely NOTICE
poisonous. Whenever an engine is installed indoors the
When connecting the generator to any buildings
exhaust fumes must be vented to the outside. The engine
electrical system ALWAYS consult with a licensed
should be installed at least two feet from any outside wall.
electrician.
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.

GENERAL INFORMATION
GENERATOR OPEN DELTA EXCITATION SYSTEM
The MQ Power Model DCA300SSC is a generator (Figure The DCA300SSC generator is equipped with the state of
3) that is designed as a high quality portable (requires a the art “Open-Delta” excitation system. The open delta
trailer for transport) power source for telecom sites, lighting system consist of an electrically independent winding
facilities, power tools, submersible pumps and other wound among stationary windings of the AC output
industrial and construction machinery. section.
ENGINE OPERATING PANEL There are four connections of the open delta A, B, C and
The “Engine Operating Panel” is provided with the following: D. During steady state loads, the power from the voltage
 Tachometer regulator is supplied from the parallel connections of A to
 Emergency Stop Switch B, A to D, and C to D. These three phases of the voltage
 Water Temperature Gauge input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
 Oil Pressure Gauge
 Charging Ammeter Gauge When a heavy load, such as a motor starting or a short
 Fuel Level Gauge circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
 Pre-Heat Lamp
connection of B to C. This has the effect of adding the
 Engine Speed Switch
voltages of each phase to provide higher excitation to the
 Battery Switch exciter section and thus better voltage response during the
 Engine Alarm Lamps (5) application of heavy loads.
GENERATOR CONTROL PANEL The connections of the AVR to the AC output windings are
The “Generator Control Panel” is provided with the following: for sensing only. No power is required from these windings.
 Frequency Meter (Hz) The open-delta design provides virtually unlimited excitation
 AC Ammeter (Amps) current, offering maximum motor starting capabilities. The
 AC Voltmeter (Volts) excitation does not have a “fixed ceiling” and responds
 Ammeter Change-Over Switch according the demands of the required load.
 Voltmeter Change-Over Switch ENGINE
 Voltage Regulator The DCA300SSC is powered by a 6 cylinder, 4-cycle water
 Panel Light/Panel Light Switch cooled, direct injection, turbocharged, charge air cooled
 3-Pole, 800 amp Main Circuit Breaker Cummins QSL9-G3 diesel engine. This engine is designed
 “Control Box” (located behind the Gen. Control Panel) to meet every performance requirement for the generator.
• Automatic Voltage Regulator Reference Table 2 for engine specifications.
• Current Transformer In keeping with MQ Power’s policy of constantly improving
• Over-Current Relay its products, the specifications quoted herein are subject
• Starter Relay to change without prior notice.
• Engine Controller (Computer Controlled) ELECTRIC GOVERNOR SYSTEM
OUTPUT TERMINAL PANEL The electric governor system controls the RPMs of the engine.
The “Output Terminal Panel” is provided with the following: When the engine demand increases or decreases, the
 Three 120/240V output receptacles (CS-6369), 50A governor system regulates the frequency variation to ±.25%.
 Three auxiliary circuit breakers, 50A EXTENSION CABLES
 Two 120V output receptacles (GFCI), 20A When electric power is to be provided to various tools or
 Two GFCI circuit breakers, 20A loads at some distance from the generator, extension cords
 Eight output terminal lugs (3Ø power) are normally used. Cables should be sized to allow for
 Battery Charger (Optional) distance in length and amperage so that the voltage drop
 Water Heater (Optional) 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. DESCRIPTION
1 Muffler Assembly
2 Engine Assembly
3 Enclosure Assembly
4 Generator Assembly
5 Output Terminal Assembly
6 Battery Assembly
7 Fuel Tank Assembly
8 Generator Control Panel Assembly
9 Engine Operating Panel Assembly
Figure 3. Major Components

GENERATOR CONTROL PANEL
Figure 4. Generator Control Panel
The definitions below describe the controls and functions the controller will shutdown the engine by initializing
of the DCA300SSC Generator Control Panel (Figure 4). the Over Speed Protection mode.
1. Pilot Lamp — Indicates the system is running. 5. Main Circuit Breaker — This three-pole, 800 amp
main breaker is provided to protect the U,V, and W
2. Panel Light — Normally used in dark areas or at night
Output Terminal Lugs from overload.
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel 6. Voltmeter Change-Over Switch — This switch allows
light switch to the OFF position. the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
3. AC Voltmeter — Indicates the output voltage present
be switched off.
at the U,V, and W Output Terminal Lugs.
7. Voltage Regulator Control — Allows ±15% manual
4. Auto On/Off Engine Controller (MPEC) —
adjustment of the generator’s output voltage.
This controller has a vertical row of status LED’s (inset),
8. Panel Light Switch — When activated will turn on
that when lit, indicate that an engine malfunction (fault)
control panel light.
has been detected. When a fault
has been detected the engine 9. Ammeter Change-Over Switch — This switch allows
controller will evaluate the fault the AC ammeter to indicate the current flowing to the load
and all major faults will shutdown connected to any phase of the output terminals, or to be
the generator. During cranking switched off. This switch does not effect the generator
cycle, The MPEC will attempt to output in any fashion, it is for current reading only.
crank the engine for 10 seconds
10. AC Ammeter — Indicates the amount of current the
before disengaging.
load is drawing from the generator per leg selected by
If the engine does not engage (start) by the third the ammeter phase-selector switch.
attempt, the engine will be shutdown by the engine
11. Frequency Meter — Indicates the output frequency
controller’s Over Crank Protection mode. If the
in hertz (Hz). Normally 60 Hz
engine engages at a speed (RPM’s) that is not safe,

GENERATOR CONTROL PANEL
 MPEC Control Switch — This switch controls the The Control Box is equipped with the following major
running of the unit. If this switch is set to the OFF/RESET components:
position, the unit will not run. When this switch is set to the
 Over-Current Relay
manual position, the generator will start immediately.
 Voltage Rectifier (AVR)
If the generator is to be connected to a building’s AC
power source via a transfer switch (isolation), place the  Starter Relay
switch in the AUTO position. In this position, should an
outage occur, the automatic transfer switch (ATS) will  Current Transformer
start the generator automatically via the generator’s auto-  Voltage Change-Over Board
start contacts conn ected to the ATS’s start contacts.
Please refer to your ATS installation manual for further  Three Phase Circuit Breaker
instructions for the correct installation of the auto-start NOTICE
contacts of the geerator to the ATS.
Remember the overcurrent relay monitors the current
 Low Oil Pressure — Indicates the engine pressure flowing from the U,V, and W Output Terminal Lugs
has fallen below a safe operating level. The oil pressure to the load.
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major In the event of a short circuit or over current condition,
fault. it will automatically trip the 800 amp main breaker.
 High Coolant Temperature — Indicates the engine To restore power to the Output Terminal Panel, press
temperature has exceeded a safe operating level. The the reset button on the overcurrent relay and place the
engine temperature is detected using variable resistive main circuit breaker in the closed position (ON).
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.
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.

ENGINE OPERATING PANEL
1 2 3 4 5 6 7 8 9
WATER TEMP. OIL PRESS. FUEL LEVEL
AIR FILTER COOLANT LEVEL
ON
OFF
Figure 5. Engine Operating Panel

The definitions below describe the controls and functions to the MANUAL position to start the engine, the
of the DCA300SSC Engine Operating Panel (Figure 5). lamp will be lit. When the oil pressure rises after
1. Tachometer — Indicates engine speed in RPM’s for 60 start-up the lamp will go OFF. If this lamp is ever
Hz operation. This meter should indicate 1800 RPM’s lit (ON) during normal operation of the generator,
when the rated load is applied. In addition a built in hour the emergency shutdown device will stop the engine
meter will record the number of operational hours that automatically.
the generator has been in use. c. Low Fuel Level Lamp — When this lamp
2. Oil Pressure Gauge — During normal operation this is ON, it is time to stop the engine and
gauge be should read between 28 to 85 psi. (193~586 add fuel. Remember to let the engine cool
kPa). When starting the generator the oil pressure may before adding fuel.
read a little higher, but after the engine warms up the oil d. Air Filter Alarm — When the air filter
pressure should return to the correct pressure range. element is clogged, this lamp goes ON
3. Water Temperature Gauge — During normal operation indicating the element should be
this gauge be should read between 167° and 203°F immediately cleaned or replaced.
(75°~95°C). e. Coolant Level Alarm — This lamp
4. Charging Ammeter Gauge — Indicates the current goes ON when the coolant level is
being supplied by the engine’s alternator which low. If this lamp goes ON while the
provides current for generator’s control circuits and engine is in operation, the emergency
battery charging system. shutdown device will automatically stop
the engine.
5. Fuel Gauge — Indicates amount of diesel fuel available.
7. Engine Speed Switch — This switch controls the
6. Engine Warning Lamps — There are three engine
speed of the engine (low/high).
warning lamps, they are defined as follows:
8. Pre-Heat Lamp — When ECU is placed in AUX
a. Overheat Lamp — This lamp goes ON
position, pre-heat lamp will be ON. When pre-heat
when the cooling water temperature rises
cycle is completed, lamp will turn OFF.
abnormally. If the lamp goes ON during
normal operation of the generator, the 9. Emergency Stop Button — Push this button inward to
emergency shutdown device will stop the stop the engine in the event of an emergency. DO NOT
engine automatically. use this button as a means of stopping the engine.
b. Low Oil Pressure Lamp — During 10. Battery Switch — This switch should be set to the ON
normal operation of the generator this position during normal operation. When the engine has
lamp should remain OFF. When the been stop, place this switch in the OFF position. DO
Auto-OFF/Reset-Manual switch is set NOT turn this switch during normal operation, it could
cause damage to the electrical equipment.

NOTES

OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION
The Output Terminal Panel (Figure 6) shown below is The “Output Terminal Panel ” (Figure 6) is provided with
located on the right-hand side (left from control panel) of the following:
the generator. Lift up on the cover to gain access to
 Three (3) 240/139V output receptacles @ 50 amp
receptacles and terminal lugs.
 Three (3) Circuit Breakers @ 50 amps
NOTICE
 Two (2) 120V GFCI receptacles @ 20 amp
Terminal legs “O” and “Ground” are considered bonded
grounds  Two (2) GFCI Circuit Breakers @ 20 amps
 Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
Figure 6. Output Terminal Panel

120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
There are two 120 VAC, 20 amp GFCI (Duplex Nema GFCI receptacles. Remember the load output (current) on
5-20R) receptacles provided on the output terminal panel. all three receptacles is dependent on the load requirements
These receptacles can be accessed in any voltage of the Output Terminal Lugs.
selector switch position. Each receptacle is protected by a
20 amp circuit breaker. These breakers are located directly Turn the voltage regulator control knob (Figure 9) on the
above the GFCI receptacles. Remember the load output control panel to obtain the desired voltage. Turning the knob
(current) of both GFCI receptacles is dependent on the load clockwise will increase the voltage, turning the knob
requirements of the U, V, and W output terminal lugs. counter-clockwise will decrease the voltage.
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.
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 selector switch is placed in the single-
phase 240/120 position.
Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

Connecting Loads Over Current Relay
Loads can be connected to the generator by the Output An over current relay (Figure 11) is connected to the main
Terminal Lugs or the convenience receptacles (Figure 10). circuit breaker. In the event of an overload, both the circuit
Make sure to read the operation manual before attempting breaker and the over current relay may trip. If the circuit
to connect a load to the generator. breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
To protect the output terminals from overload, a 3-pole,
located in the control box.
800A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 11. Over Current Relay
Figure 10. Connecting Loads

LOAD APPLICATION
SINGLE PHASE LOAD THREE PHASE LOAD
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase
and equipment to insure the wattage, amperage, frequency, power use the following equation:
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 NOTICE
130—150% more wattage than the rating on the nameplate, If 3Ø load (kVA) is not given on the equipment
as the wattage is influenced by the efficiency, power factor nameplate, approximate 3Ø load may be determined
and starting system of the equipment. by multiplying voltage by amperage by 1.732
NOTICE
If wattage is not given on the equipment’s name plate, NOTICE
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage. Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which cannot carry
The power factor of this generator is 0.8. See Table 5 below the required load can cause a voltage drop which can
when connecting loads. burn out the appliance or tool and overheat the cable. See
Table 6.
Table 5. Power Factor By Load
Type of Load Power Factor  When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
Single-phase induction motors 0.4-0.75 the generating set’s rated output (kW) can be used.
Electric heaters, incandescent lamps 1.0  When connecting a fluorescent or mercury lamp, a
Fluorescent lamps, mercury lamps 0.4-0.9 capacity of up to the generating set’s rated output (kW)
Electronic devices, communication multiplied by 0.6 can be used.
1.0
equipment  When connecting an electric drill or other power tools,
Common power tools 0.8 pay close attention to the required starting current
capacity.
Table 6. Cable Selection (60 Hz, Single Phase Operation) When connecting ordinary power tools, a capacity of up to
Current Load in Watts Maximum Allowable Cable Length the generating set’s rated output (kW) multiplied by 0.8 can
in
Amperes
At 100 At 200 #10 Wire #12 Wire #14 Wire #16 Wire
be used.
Volts Volts
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft. DANGER
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
Before connecting this generator to any building’s
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft. electrical system, a licensed electrician must install
10 1200 2400 250 ft. 150 ft. 100 ft. an isolation (transfer) switch. Serious damage to
15 1800 3600 150 ft. 100 ft. 65 ft. the building’s electrical system may occur without this
20 2400 4800 125 ft. 75 ft. 50 ft. transfer switch.
CAUTION: Equipment damage can result from low voltage

GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES Maximum Amps
A wide range of voltages are available to supply voltage Table 8 shows the maximum amps the generator can
for many different applications. Voltages are selected by provide. DO NOT exceed the maximum amps as listed.
applying jumpers (6) to the voltage change-over board
(Figure 12). To obtain some of the voltages as listed in Table 8. Generator Maximum Amps
Table 7 (see below) will require a fine adjustment using
the voltage regulator (VR) control knob located on the Model DCA300SSC
control panel.
Rated Voltage Maximum Amps
Voltage Change-Over Board
Single Phase 120 Volt 666.7 amps (4 wire)
The voltage change-over board (Figure 12) is located on
the control box, behind the generator control panel. This Single Phase 240 Volt 333.3 amps (4 wire)
board has been provided for ease of voltage selection.
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!
Table 7. Voltages Available

Three Phase
208V 220V 240V 416V 440V 480V
(Switchable)
Single Phase
120V 127V 139V 240V 254V 277V
(Switchable)

GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC AC Ammeter Gauge Reading
VOLTAGE GAUGES
Place the AC Ammeter Change-Over Switch (Figure 16)
The AC ammeter and AC voltmeter gauges are controlled in the U position and observe the current reading (load
by the AC ammeter and AC voltmeter change-over drain) on the U terminal as indicated on the AC Ammeter
switches. Gauge (Figure 17). This process can be repeated for
terminals V and W.
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.
Figure 16. AC Ammeter Figure 17. AC Ammeter
Change-Over Switch (Amp reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 13. Voltage Change-Over Board

240/3Ø 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 Figure 15. AC Voltmeter Gauge

Change-Over Switch (Volt reading on W-U Lug)

OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
Various output voltages can be obtained using the UVWO decrease voltage output. Use voltage regulator
output terminal lugs. The voltages at the terminals are adjustment knob whenever fine tuning of the output
dependent on the placement of the jumpers plates (6) on voltage is required
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 Figure 20. Voltage Regulator Knob
different positions that provide 6 different output voltages
1Ø-240V UVWO Terminal Output Voltages
at the UVWO output terminals. The generator is shipped
from the factory in the 240V configuration. The voltage 1. Make sure the voltage change-over board is jumpered
regulator (VR) allows the user to increase or decrease the for 240V operation as shown in Figure 18.
selected voltage. 2. Connect the load wires to the UVWO terminals as
shown in Figure 21.
1. Jumper the voltage change-over board for 240V
operation as shown in Figure 18.
Figure 21. UVWO Terminal Lugs 1Ø-240V

Connections
1. Make sure the voltage change-over board is jumpered
Figure 18. Voltage Change-Over Board 240V for 240V operation as shown in Figure 18.
Configuration 2. Adjust voltage regulator knob (Figure 20) for an output
2. Connect the load wires to the UVWO terminals as of 208V to obtain 120V at the UVWO terminals.
shown in Figure 19. 3. Connect the load wires to the UVWO terminals as
shown in Figure 22.
Figure 19. UVWO Terminal Lugs

Connections

OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages 1Ø-480V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 480V 1. Make sure the voltage change-over board is jumpered
operation as shown in Figure 23. This configuration for 480V operation as shown in Figure 23.
uses 6 jumper plates in 3 different positions. Remember
2. Connect the load wires to the UVWO terminals as
there are 2 jumper plates at every position. Every
shown in Figure 25.
jumper plate must be used.

Connections
Figure 23. Voltage Change-Over Board 480V
Configuration 1Ø-277V UVWO Terminal Output Voltages
2. Connect the load wires to the UVWO terminals as 1. Make sure the voltage change-over board is jumpered
shown in Figure 24. for 480V operation as shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure 26.

Connections
NOTICE Figure 26. UVWO Terminal Lugs 1Ø-277V
ALWAYS make sure that the connections to the UVWO Connections
terminals are secure and tight. The possibility of arcing
exists, that could cause a fire.

INSPECTION/SETUP
CIRCUIT BREAKERS FUEL CHECK
To protect the generator from an overload, a 3-pole, 800 DANGER
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two Fuel spillage on a hot engine can cause
single-pole, 20 amp GFCI circuit breakers are provided to a fire or explosion. If fuel spillage occurs,
protect the GFCI receptacles from overload. Three 50 amp wipe up the spilled fuel completely to
load circuit breakers have also been provided to protect the prevent fire hazards. NEVER smoke
auxiliary receptacles from overload. Make sure to switch around or near the generator.
ALL circuit breakers to the OFF position prior to starting
the engine. Refilling the Fuel System
LUBRICATION OIL
CAUTION
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is ONLY properly trained personnel who have read
level and verify that the oil level is maintained between the and understand this section should refill the fuel tank
two notches (Figure 27) on the dipstick. See Table 9 for system.
proper selection of engine oil.
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.
Figure 27. Engine Oil Dipstick Pay attention to the fuel tank capacity when replenishing
When checking the engine oil, be sure to check if the oil is fuel. The fuel tank cap must be closed tightly after filling.
clean. If the oil is not clean, drain the oil by removing the Handle fuel in a safety container. If the container does not
oil drain plug, and refill with the specified amount of oil as have a spout, use a funnel. Wipe up any spilled fuel
outlined in the Cummins Engine Owner’s Manual. Oil immediately.
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
Figure 28. Internal Fuel Tank System

INSPECTION/SETUP
Refueling Procedure: 2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
WARNING cap and fill tank (Figure 30).
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. 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
Figure 31. Full Fuel Tank
ONLY use #2 diesel fuel when refueling.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 32).
Figure 32. Fuel Expansion

INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/ The engine may overheat if the radiator fins become
WATER) overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
Cummins recommends antifreeze/summer coolant for use in machine is dangerous, so clean only with the engine turned
their engines, which can be purchased in concentrate (and off and the negative battery terminal disconnected.
mixed with 50% demineralized water) or pre-diluted. See the
Cummins Engine Owner’s Manual for further details. AIR CLEANER
WARNING Periodic cleaning/replacement is necessary. Inspect air

cleaner in accordance with the Cummins Engine Owner’s
If adding coolant/antifreeze mix to the Manual.
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The FAN BELT TENSION
possibility of hot! coolant exists which can
A slack fan belt may contribute to overheating, or to
cause severe burns.
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
Day-to-day addition of coolant is done from the recovery Cummins Engine Owner’s Manual.
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See The fan belt tension is proper if the fan belt bends 10 to 15
Table 10 for engine, radiator, and recovery tank coolant mm (Figure 33) when depressed with the thumb as shown
capacities. Make sure the coolant level in the recovery tank below.
is always between the “H” and the “L” markings.
Table 10. Coolant Capacity

Engine and Radiator 15.8 Gal (60 liters)
Reserve Tank N/A
Operation in Freezing Weather
When operating in freezing weather, be certain the proper Figure 33. Fan Belt Tension
amount of antifreeze (Table 11) has been added. CAUTION
Table 11. Anti-Freeze NEVER place hands near the belts or fan
Operating Temperatures while the generator set is running.
Vol % Freezing Point

Anti-Freeze °C °F
50 -37 -34
Cleaning the Radiator

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

INSPECTION/SETUP
BATTERY When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified terminals when the MPEC Control Switch is in either
marks. Battery life will be shortened, if the fluid level are the MANUAL position. ALWAYS make sure that the
not properly maintained. Add only distilled water when MPEC Control Switch is in the OFF/RESET position
replenishment is necessary. when connecting the battery.
DO NOT over fill. Check to see whether the battery 2. Place a small amount of battery terminal treatment
cables are loose. Poor contact may result in poor starting compound around both battery terminals. This will
or malfunctions. Always keep the terminals firmly ensure a good connection and will help prevent
tightened. Coating the terminals with an approved battery corrosion around the battery terminals.
terminal treatment compound. Replace battery with only NOTICE
recommended type battery. The battery type used in this
generator is BCI Group 27. If the battery cable is connected incorrectly, electrical
damage to the generator will occur. Pay close attention to
The battery is sufficiently charged if the specific gravity the polarity of the battery when connecting the battery.
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. CAUTION
Before charging the battery with an external electric source, Inadequate battery connections may cause poor starting
be sure to disconnect the battery cables. of the generator, and create other malfunctions.
Battery Cable Installation

ALTERNATOR
ALWAYS be sure the battery cables (Figure 34) are properly
connected to the battery terminals as shown below. The The polarity of the alternator is negative grounding type.
red cable is connected to the positive terminal of the When an inverted circuit connection takes place, the
battery, and the black cable is connected to the negative circuit will be in short circuit instantaneously resulting the
terminal of the battery. alternator failure.
CAUTION DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrosion and damage the
ALWAYS disconnect the negative terminal FIRST and alternator.
reconnect negative terminal LAST.
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.
Figure 34. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.

GENERATOR START-UP PROCEDURE (MANUAL)
BEFORE STARTING STARTING (MANUAL)
CAUTION 1. Place the engine speed switch (Figure 37) in the LOW
(down) position.
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
Figure 37. Engine Speed Switch (Low)
WARNING
2. Place the MPEC control switch in the MANUAL
NEVER manually start the engine with the main, GFCI or position to start the engine (Figure 38).
auxiliary circuit breakers in the ON (closed) position.
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
Figure 35. Main, Aux. and GFCI automatically.
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
Figure 39. Pre-Heat Button
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup 4. Once the engine starts, let the engine run for 1-2
panel. minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
4. Tighten terminal nuts securely to prevent load wires the problem. If the engine is running smoothly, place
from slipping out. the engine speed switch (Figure 40) in the HIGH (up)
5. Close all engine enclosure doors (Figure 36). position.
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
CORRECT INCORRECT engine has been started.
Figure 36. Engine Enclosure Doors
Figure 41. Engine Running LED (ON)

GENERATOR START-UP PROCEDURE (MANUAL)
6. The generator’s frequency meter (Figure 42) should be 10. The coolant temperature gauge (Figure 47) will
displaying the 60 cycle output frequency in HERTZ. 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
11. The tachometer gauge (Figure 48) will indicate the
Figure 42. Frequency Meter speed of the engine when the generator is operating.
7. The generator’s AC-voltmeter (Figure 43) will display Under normal operating conditions this speed is
the generator’s output in VOLTS. If the voltage is not approximately 1800 RPM’s.
within the specified tolerance, use the voltage
adjustment control knob (Figure 44) to increase or
decrease the desired voltage.
Figure 48. Engine Tachometer Gauge

12. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 49).
Figure 43. Voltmeter
Figure 44. Voltage Adjust Control Knob

8. The ammeter (Figure 45) will indicate zero amps with
no load applied. When a load is applied, the ammeter Figure 49. Main, Aux. and GFCI
will indicate the amount of current that the load is Circuit Breakers (ON)
drawing from the generator.
13. 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)

9. The engine oil pressure gauge (Figure 46) will indicate
the oil pressure of the engine. Under normal operating Figure 50. Ammeter (Load)
conditions the oil pressure is approximately 28 to 85
14. The generator will run until manually stopped or an
psi. (193~586 kPa).
abnormal condition occurs.
Figure 46. Oil Pressure Gauge

GENERATOR START-UP PROCEDURE (AUTO MODE)
STARTING (AUTO MODE) When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
DANGER
1. Perform steps 1 through 5 in the Before Starting section
Before connecting this generator to any as outlined in the Manual Starting Procedure.
building’s electrical system, a licensed
electrician must install an isolation 2. Place the engine speed switch (Figure 51) in the
(transfer) switch. Serious damage to HIGH position
the building’s electrical system may occur without this
transfer switch.
CAUTION Figure 51. Engine Speed Switch (High)

When connecting the generator to a isolation (transfer) 3. Place the MPEC Control Switch (Figure 52) in the
switch, ALWAYS have power applied to the generator’s AUTO position.
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
Figure 52. MPEC Control Switch (AUTO)
generator will automatically start in the event of
commercial power falling below a prescribed level 4. Continue operating the generator as outlined in the
by means of a contact closure that is generated Manual Start-up procedure (start at step 5).
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.

GENERATOR SHUT-DOWN PROCEDURES
WARNING EMERGENCY SHUTDOWN PROCEDURE
NEVER stop the engine suddenly except in an 1. To stop the engine in the event of an emergency, PUSH
emergency. the emergency stop button (Figure 55) inward. This
button is located on the engine operating panel, see
NORMAL SHUTDOWN PROCEDURE Figure 5.
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
10 Hrs 1000
Table 12. Inspection/Maintenance 250 Hrs 500 Hrs
DAILY Hrs
Check Engine Fluid Levels X
Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Parts X
Replace Engine Oil and Filter * 1 X
Engine Clean Air Filter X
Check Fuel Filter/Water Separator Bowl X
Clean Unit, Inside and Outside X
Change Fuel Filter X
Clean Radiator and Check Coolant Protection Level*2 X
Replace Air Filter Element * 3 X
Check all Hoses and Clamps * 4 X
Clean Inside of Fuel Tank X
Measure Insulation Resistance Over 3M ohms X
Generator
Check Rotor Rear Support Bearing X
*1 Replace engine oil and filter at 100 hours, first time only.
*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 14 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 56)
and clean the heavy duty paper element with light spray of Figure 56. Air Cleaner/Indicator
compressed air. Replace the air cleaner as needed. NOTICE
Air Cleaner with Dust Indicator The air filter should not be changed until the indicator
This indicator (Figure 56) is attached to the air cleaner. reads “RED”. Dispose of old air filter. It may not be
When the air cleaner element is clogged, air intake cleaned or reused..
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.

MAINTENANCE
If the engine is operating in very dusty or dry grass FUEL TANK INSPECTION
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion In addition to cleaning the fuel tank, the following
chamber and high fuel consumption. Change air cleaner components should be inspected for wear:
more frequently if these conditions exists.  Rubber Suspension — look for signs of wear or
FUEL ADDITION deformity due to contact with oil. Replace the rubber
suspension if necessary.
Add diesel fuel (the grade may vary according to season
 Fuel Hoses — inspect nylon and rubber hoses for signs
and locations).
of wear, deterioration and hardening.
Removing Water from the Fuel Tank  Fuel Tank Lining — inspect the fuel tank lining for signs
After prolonged use, water and other impurities accumulate of excessive amounts of oil or other foreign matter.
in the bottom of the tank. Occasionally inspect the fuel Replacing Fuel Filter
tank for water contamination and drain the contents if
required.  Replace the fuel filter cartridge with new one every 500
hours or so.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be  Loosen the drain plug at the lower top of the fuel filter.
reduced by keeping the tank full with diesel fuel. Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Cleaning Inside the Fuel Tank
 Vent any air
Drain the fuel inside the fuel tank completely. Using a spray
washer (Figure 57) wash out any deposits or debris that AIR REMOVAL
have accumulated inside the fuel tank. 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

MAINTENANCE
To restart after running out of fuel, turn the switch to the RADIATOR CLEANING
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system. The radiator (Figure 58) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
CHECK OIL LEVEL and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
Check the crankcase oil level prior to each use, or when the (1.5 meters) away from the radiator to prevent damage to
fuel tank is filled. Insufficient oil may cause severe damage the fins and tube.
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.
Figure 58. Radiator Cleaning
FLUSHING OUT RADIATOR AND REPLACING
COOLANT GENERATOR STORAGE
For long term storage of the generator the following is
 Open both cocks located at the crankcase side and at
recommended:
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow  Drain the fuel tank completely. Treat with a fuel stabilizer
tank and drain. if necessary.
 Check hoses for softening and kinks. Check clamps for  Completely drain the oil from the crankcase and refill if
signs of leakage. necessary with fresh oil.
 Tighten both cocks and replace the overflow tank.  Clean the entire generator, internal and external.
 Replace with coolant as recommended by the engine  Cover the generating set and store in a clean, dry place.
manufacturer.
 Disconnect the battery.
 Close radiator cap tightly.
 Make sure engine coolant is at proper level.
 Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO  If generator is mounted on a trailer, jack trailer up and
NOT clean radiator core with any objects, such as a place on blocks so tires do not touch the ground or block
screwdriver. and completely remove the tires.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.

MAINTENANCE
JACKET WATER HEATER AND INTERNAL BATTERY If the generator will be used daily, the battery should
CHARGER 120 VAC INPUT RECEPTACLES normally not require charging. If the generator will be idle
(OPTIONAL) (not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
This generator can be optionally equipped with two 120 power cord of adequate size.
VAC, 20 amp input receptacles located on the output
terminal panel. NOTICE
The purpose of these receptacles is to provide power via To ensure adequate starting capability, always have
commercial power to the jacket water heater and internal power applied to the generator's internal battery
battery charger. 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.
Figure 59. Battery Charger and Jacket Water

Heater Power Connections

TRAILER MAINTENANCE
TRAILER MAINTENANCE 8. Tire Size — Indicates the diameter of the tire in
inches (10,12,14, etc.), and the width in millimeters
This section is intended to provide the user with generic (175,185,205, etc.). The tire diameter must match the
trailer service and maintenance information. The service diameter of the tire rim.
and maintenance guidelines referenced in this section refer
to a wide range of trailers. 9. Tire Ply — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and 10. Wheel Hub — The wheel hub is connected to the
damage to the equipment. trailer’s axle.
The definitions below describe some of the major 11. Tire Rim — Tires mounted on a tire rim. The tire rim
components of a typical trailer that would be used with must match the size of the tire.
the generator. 12. Lug Nuts — Used to secure the wheel to the wheel
1. Fuel Cell — Provides an adequate amount of fuel for hub. Always use a torque wrench to tighten down
the equipment in use. Fuel cells must be empty when the lug nuts. See Table 18 and Figure 62 for lug nut
transporting equipment. tightening and sequence.
2. Braking System — System employed in stopping 13. Axle — Indicates the maximum weight the axle can
the trailer. Typical braking systems are electric, surge, support in pounds, and the diameter of the axle
hydraulic, hydraulic-surge and air. expressed in inches. Please note that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
3. GVWR — Gross Vehicle Weight Rating (GVWR) is meaning two axles with a total weight capacity of 6000
the maximum number of pounds the trailer can carry, pounds.
including the fuel cell (empty).
14. Suspension — Protects the trailer chassis from shocks
4. Frame Length — Measurement is from the ball hitch transmitted through the wheels. Types of suspension
to the rear bumper (reflector). used are leaf, Q-flex, and air ride.
5. Frame Width — Measurement is from fender to 15. Electrical — Electrical connectors (looms) are provided
fender with the trailer so the brake lights and turn signals can
6. Jack Stand — Trailer support device with maximum be connected to the towing vehicle.
pound requirement from the tongue of the trailer. 16. Application — Indicates which units can be employed
7. Coupler — Type of hitch used on the trailer for on a particular trailer.
towing.

TRAILER MAINTENANCE
BRAKES Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 60) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should
every 3,000 miles. If driving over rough terrain, inspect the be periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 60 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as listed below:
Brake Adjustment
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. Figure 60. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate Actuator
the star wheel of the adjuster assembly to expand the
brake shoes. Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
5. Adjust the brake shoes outward until the pressure of or push of the trailer toward the tow vehicle automatically
the lining against the wheel drum makes the wheel synchronizes the trailer brakes with the tow vehicle brakes.
difficult to turn. As the trailer pushes against the tow vehicle the actuator
6. Adjust, rotate the star wheel in the opposite direction telescopes together and applies force to the master cylinder,
until the wheel rotates freely with slight lining drag. supplying hydraulic pressure to the trailer brakes.
7. Replace the adjusting hole cover and lower the trailer Periodically check and test the surge “actuator” to make sure that
to the ground. it is functioning correctly. Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 13. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution
No Brakes Brake line broken or kinked? Repair or replace.
Brake lining glazed? Reburnish or replace.
Trailer overloaded? Correct weight.
Weak Brakes or Brakes Pull to
Brake drums scored or grooved? Machine or replace.
One Side
Tire pressure correct? Inflate all tires equally.
Tires unmatched on the same axle? Match tires.
Brake components loose, bent or
Replace components.
Locking Brakes broken?
Brake drums out-of-round? Replace.
System lubricated? Lubricate.
Noisy Brakes
Brake components correct? Replace and correct.
Brake lining thickness incorrect or Install new shoes and
not adjusted correctly? linings.
Dragging Brakes
Replace rubber parts
Enough brake fluid or correct fluid?
fill with dot 4 fluid.

TRAILER MAINTENANCE
TIRES/WHEELS/LUG NUTS Suspension
Tires and wheels are a very important and critical The leaf suspension springs and associated components
components of the trailer. When specifying or replacing the (Figure 61) should be visually inspected every 6,000 miles
trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and
properly matched. loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
CAUTION
as detailed in Table 17.
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 Figure 61. Major Suspension Components

Tire inflation pressure is the most important factor in tire Table 15. Suspension Torque Requirements
life. Pressure should be checked cold before operation DO Item Torque (Ft.-Lbs.)
NOT bleed air from tires when they are hot!. Check inflation
3/8" U-Bolt Min-30 Max-35
pressure weekly during use to insure the maximum tire life
and tread wear. 7/16" U-Bolt Min-45 Max-60
Table 16 (Tire Wear Troubleshooting) will help pinpoint the 1/2" U-Bolt Min-45 Max-60
causes and solutions of tire wear problems. Shackle Bolt Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Table 14. Tire Wear Troubleshooting Spring Eye Bolt provided to retain nut-bolt assembly.
Wear Pattern Cause Solution
Shoulder Type
Adjust pressure to particular Min-30 Max-50
Center Wear Over inflation.
load per tire manufacturer. Shackle Bolt
Adjust pressure to particular

Edge Wear Under inflation.
load per tire manufacturer.
Make sure load does not

Loss of camber
Side Wear exceed axle rating.
or overloading.
Align wheels.
Toe Wear Incorrect toe-in. Align wheels.
Check bearing adjustment

Cupping Out-of-balance.
and balance tires.
Wheel lockup and Avoid sudden stops when

Flat Spots
tire skidding. possible and adjust brakes.

TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 62). DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 16. Tire Torque Requirements
First Pass Second Pass Third Pass
Wheel Size
FT-LBS FT-LBS FT-LBS
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
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

GENERATOR WIRING DIAGRAM
Figure 64. Generator Wiring Diagram

ENGINE WIRING DIAGRAM
Figure 65. Engine Wiring Diagram

NOTES

TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Table 17. Generator Troubleshooting
Symptom Possible Problem Solution
AC Voltmeter defective? Check output voltage using a voltmeter.
Is wiring connection loose? Check wiring and repair.
No Voltage Output 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”.
Low Voltage Output Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
High Voltage Output
Defective AVR? Replace if necessary.
Short Circuit in load? Check load and repair.
Over current? Confirm load requirements and reduce.
Circuit Breaker Tripped
Defective circuit breaker? 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 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
Table 18. Engine Controller Troubleshooting (MPEC)

Symptom Possible Problem Solution
Low oil level? Fill oil level.
Oil pressure sending unit failure? Replace oil pressure sending unit.
Low oil pressure light is on.
Time delay malfunction in controller? Refer to dealer.
Wire shorted? Inspect/repair wire.
Low coolant level? Fill coolant level.
Low coolant level light is on.
Sending unit failure? Replace sending unit.
(Optionally installed)
Low battery voltage? Replace/charge battery.
Fan belt tension incorrect? Tighten/replace fan belt.
Air flow is not circulating through radiator? Clean/repair radiator grill.
Doors open? Close doors.
High coolant temperature Exhaust leaking? Replace/repair gaskets or faulty part.
light is on. Generator being overloaded? Check/reduce load.
Thermostat failure? Replace thermostat.
Air intake blocked? Clean all air intakes.
Temperature switch failure Replace temperature switch.
No or low fuel? Fill fuel level.
Overcrank light is on.
Controller needs to be calibrated? Refer to dealer.
RPM engine speed too high? Adjust RPM.
Governor actuator needs to be adjusted? Adjust governor actuator.
Overspeed light is on.
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.
Loss of MPU light(s) or on.
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 QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there Numbers Used — Item quantity can be indicated by a
are any questions. number, a blank entry, or A/R.
NOTICE A/R (As Required) is generally used for hoses or other

parts that are sold in bulk and cut to length.
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip A blank entry generally indicates that the item is not sold
does not guarantee the availability of the parts listed. separately. Other entries will be clarified in the “Remarks”
Column.
SAMPLE PARTS LIST REMARKS Column
NO. PART NO. PART NAME QTY. REMARKS
Some of the most common notes found in the “Remarks”
1 12345 BOLT .....................1 .....INCLUDES ITEMS W/%
2% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY Column are listed below. Other additional notes needed
2% 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY to describe the item can also be shown.
3 12348 HOSE ..................A/R ...MAKE LOCALLY
4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
NO. Column purchased.
Unique Symbols — All items with same unique Indicated by:
symbol “INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the Serial Number Break — Used to list an effective serial
same assembly or kit, which is indicated by a note in the number range where a particular part is used.
“Remarks” column.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate “S/N XXXXX AND BELOW”
multiple part numbers, which are in effect for the same “S/N XXXX AND ABOVE”
general item, such as different size saw blade guards in “S/N XXXX TO S/N XXX”
use or a part that has been updated on newer versions
of the same machine. Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
NOTICE number variant listed. It can also be used to show a
When ordering a part that has more than one item part is NOT used on a specific model or model number
number listed, check the remarks column for help in variant.
determining the proper part to order. Indicated by:
“XXXXX ONLY”
PART NO. Column
“NOT USED ON XXXX”
Numbers Used — Part numbers can be indicated by a “Make/Obtain Locally” — Indicates that the part can
number, a blank entry, or TBD. be purchased at any hardware shop or made out of
TBD (To Be Determined) is generally used to show a available items. Examples include battery cables, shims,
part that has not been assigned a formal part number and certain washers and nuts.
at the time of publication. “Not Sold Separately” — Indicates that an item cannot
A blank entry generally indicates that the item is not sold be purchased as a separate item and is either part of an
separately or is not sold by Multiquip. Other entries will assembly/kit that can be purchased, or is not available
be clarified in the “Remarks” Column. for sale through Multiquip.

SUGGESTED SPARE PARTS
DCA300SSC WHISPERWATT GENERATOR WITH
CUMMINGS QSL9-G3 DIESEL ENGINE
1 to 3 units
QTY. P/N DESCRIPTION
1............0602015120..........HOSE, RADIATOR UPPER ENGINE
1............0602015121..........HOSE, RADIATOR UPPER/LOWER
1............0602015122..........HOSE, RADIATOR LOWER
3............0602015244..........BELT, FAN
1............4921744................SENSOR, OIL PRESSURE
1............0602122272..........OIL PRESSURE UNIT
1............0602123267..........WATER TEMPERATURE UNIT
1............0602210189..........WATER TEMP. SWITCH ENGINE
1............0602123290..........SWITCH, COOLANT LEVEL
6............0810105400..........FILTER, FUEL TANK
6............0602042589..........FUEL FILTER CARTRIDGE
6............0602042589..........CARTRIDGE WATER SEPERATOR
6............0602041224..........FILTER, OIL CARTRIDGE
6............0602045193..........FILTER, COOLANT CARTRIDGE
3............0602046638..........ELEMENT AIR CLEANER OUTER
3............0602046639..........ELEMENT AIR CLEANER INNER
1............0601808803..........CIRCUIT BREAKER 1P 20A
1............0601808804..........CIRCUIT BREAKER 2P 50A
2............LY2DUS24VDC ....RELAY
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.

GENERATOR ASSY.
1 C2110000002 ROTOR ASSY ..........................................1............. INCLUDES ITEMS W/#
1-1# FIELD ASSY 1
1-2# 0601842402 RESISTOR, 80W 300K 2
1-3# 0601823282 RECTIFIER 1
1-4# 0018205020 HEX HD. CAP SCREW 2
1-4A# 0040005000 WASHER, LOCK 2
1-4B# 0041205000 WASHER, FLAT 2
1-5# 8201070002 FAN 1
1-6# 8201611004 COUPLING DISK 12
1-7# C3164200004 WASHER, COUPLING HUB 1
1-8# 8201015003 BALANCING PLATE.................................1............. PURCHASE ITEM 1-11 AS A SET
1-9# 0012116045 HEX HEAD BOLT 10
1-10# 0042616000 WASHER, LOCK 10
1-11# 0601000209 BALANCING WEIGHT KIT 1
1-12# C3112500004 BEARING FLANGE 1
1-13# 0071906315 BEARING 1
2 C2163400003 COUPLING RING 1
3 0343206200 HEX HEAD BOLT 8
4 0043606000 WASHER, LOCK 8
5# 0010312040 HEX HEAD BOLT 12
5A# 0042512000 WASHER, LOCK 12
6 C2130100103 STATOR ASSY 1
6-1 0226200430 RUBBER SEAL 1
6-2 8201323004 CLAMPER 1
6-3 0223300140 RUBBER SEAL 1
6-4 8201323103 CLAMPER 1
6-5 0221200350 RUBBER SEAL 1
6-6 0010110035 HEX HEAD BOLT 2
6-6A 0041210000 WASHER, FLAT 2
6-7 C2132200003 COVER 1
6-8 0226000275 RUBBER SEAL 2
6-9 0225000500 RUBBER SEAL 1
6-10 0017106016 HEX HEAD BOLT 6
6-11 0601850144 GROMMET 1
7 C3154000002 END BRACKET 1
8 C3138000003 FIELD ASSY, EXCITER 1
9 0012110080 HEX HEAD BOLT 4
9A 0042610000 WASHER, LOCK 4
9B 0041210000 WASHER, FLAT 4
10 0017112045 HEX HEAD BOLT 8
11 C3154300104 COVER, BEARING 1
12 C3154300004 GASKET, BEARING 1
13 0010106060 HEX HEAD BOLT 4
13A 0040006000 WASHER, LOCK 4
13B 0041206000 WASHER, FLAT 4

GENERATOR ASSY. (CONTINUED)

GENERATOR ASSY. (CONTINUED)
14 C3154400003 SUCTION COVER 1
15 0017106015 HEX HEAD BOLT 8
16 C3164600103 COUPLING ADAPTER 1
17 0010310030 HEX HEAD BOLT 12
17A 0042510000 WASHER, LOCK 12
18 C2163700004 SPACER, BEARING 1
19 0070506208 BEARING, 6208ZZ 1
20 0010312040 HEX HEAD BOLT 16
20A 0042512000 WASHER, LOCK 16
21 C3132300014 COVER, FAN 1
22 0010106030 HEX HEAD BOLT 1
22A 0041206000 WASHER, FLAT 1
22B 0600815000 NUT 1
23 0605000012 RUBBER SUSPENSION 2
24 0030020000 HEX NUT 4
24A 0040020000 WASHER, LOCK 4

CONTROL BOX ASSY.

CONTROL BOX ASSY.
1 M5213000002 CONTROL BOX 1
2 0601809659 CURRENT TRANSFORMER 3
3 0027106015 MACHINE SCREW 6
4 0601807513 CIRCUIT BREAKER, 800A 1
5 C2261600204 BRACKET, CIRCUIT BREAKER 1
6 0017108020 HEX HEAD BOLT 4
7 0601820604 AUTOMATIC VOLTAGE REGULATOR 1
9 0601842468 RESISTOR, 5W 150 OHM 1
11 C2274000103 CHANGE- OVER BOARD, VOLTAGE 1
12 8201852104 CHANGE TERMINAL 10
13 0017108030 HEX HEAD BOLT 20
14 C2277200004 TERMINAL PLATE 3
15 8201853104 CHARGE PLATE 6
16 8201852504 HEX HEAD BOLT 13
17 0801830704 HEX HEAD BOLT 13
18 0040012000 WASHER, LOCK 26
19 0041412000 WASHER, FLAT 26
20 0017110030 HEX HEAD BOLT 4
21 0601820847 OVER CURRENT RELAY 1
22 0601820840 OVER CURRENT RELAY 1
23A 0207004000 HEX NUT 2
24 0601815153 TERMINAL BOARD 1
26 0601802218 HOLDER, FUSE 1
26A 0601802149 FUSE (LEFT SIDE), 10A 1
26B 0601802131 FUSE (CENTER), 1A 1
26C 0601802133 FUSE (RIGHT), 5A 1
28 C3358201704 FUSE HOLDER ASSY 1
28A 0601806644 FUSE, 30A 1
29 0601802410 BRACKET, FUSE HOLDER 1
30 0017106016 HEX HEAD BOLT 1
31 M5260500003 SET PANEL , ELECTRIC PARTS 1
32 0017108020 HEX HEAD BOLT 4
33 LY2DUS24V RELAY .........................................................4 ................REPLACES P/N 0601827655
33A PTF08A SOCKET......................................................4 ................REPLACES P/N 0601823109
33B PYCA1 HOLDER .....................................................4 ................REPLACES P/N 0601824400
35 0601823240 RECTIFIER 2
37 M5260500204 BRACKET 1
38 0602103090 DIAGNOSTIC LAMP 2
37 M5260500204 BRACKET 1
38 0602103090 DIAGNOSTIC LAMP 2

CONTROL BOX ASSY. (CONTINUED)

CONTROL BOX ASSY. (CONTINUED)
38 A 0601810244 BULB, DC28V 2
39 0601831670 DIAGNOSTIC BUTTON 1
40 0601831205 RESET BUTTON 1
41 0601830746 LOW IDLE SPEED SWITCH 1
42 0601830710 DIAGNOSTIC SWITCH 1
43 0601840009 RHEOSTAT, 2W 5k OHM 1
44 0017106016 HEX HEAD BOLT 4
45 0602201455 RELAY, HEATER ............................................. 1 ............... 1210--1004--00
46 0017106016 HEX HEAD BOLT 2
47 C2224000503 CONTROL PANEL 1
48 C2224001504 CONTROL PANEL 1
49 0605011211 PIN 2
50 0601807622 FREQUENCY METER, 45~65Hz 220V 1
51 0601806979 AC AMMETER, 0~1000A 1
52 0601801040 CHANGE- OVER SWITCH, AMMETER 1
53 0601806887 AC VOLTMETER, 0~600V 1
54 0601801041 CHANGE- OVER SWITCH, VOLTMETER 1
55 0601810072 PILOT LAMP 1
55A 0601810261 BULB, 13W 1
56 0601840073 RHEOSTAT (VR), 2W 1K OHM 1
57 0601840121 KNOB 1
58 ECU9988N220V ENGINE CONTROLLER ................................. 1 ............... REPLACES P/N 0602202545
59 0601830765 SWITCH 1
60 0601810171 PANEL LIGHT, DC24V 1
61A 0207004000 HEX NUT 2
62 0601830710 SWITCH, PANEL LIGHT 1
63 C9221100004 HEX HEAD BOLT 2
63A 0040008000 WASHER, LOCK 2
63B 0041208000 WASHER, FLAT 2
63C 0080200007 SNAP RING 2
64 0017108040 HEX HEAD BOLT 4
65 3871824004 STOPPER, CONTROL PANEL 1
66 0041206000 WASHER, FLAT 1
67 0605010502 SNAP PIN 1
68 C2214500004 COVER, CONTROL BOX 1
69 0017108020 HEX HEAD BOLT 8
70 C2214300004 SIDE PANEL, CONTROL BOX 1
71 0017108020 HEX HEAD BOLT 4
72 C2214400504 PANEL, CONTROL BOX 1
73 0017108020 HEX HEAD BOLT 9
74 0017110025 HEX HEAD BOLT 4

ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.
1 C2923200204 ENGINE, QSL9-G3 1
1A 0602015244 BELT, FAN ........................................................1 ............. 3288497
1-1 0602046638 ELEMENT, AIR CLEANER (OUTER) ..............1 ............. AF26124
1-1A 0602046639 ELEMENT, AIR CLEANER (INNER) ................1 ............. AF26125
1-2 0602041224 CARTRIDGE, OIL FILTER ...............................1 ............. LF9009
1-3 0602045193 CARTRIDGE, COOLANT FILTER....................1 ............. WF2076
1-4 0602042588 CARTRIDGE, FUEL FILTER ............................1 ............. FF5580
1-5 0602042589 CARTRIDGE, FUEL WATER SEPARATOR .....1 ............. FS19732
1-6 0602040759 CAP, AIR CLEANER ........................................1 ............. 3013238
1-7 0602040679 DUST SENSOR 1
2 M5303200004 ENGINE FOOT 1
3 0010118050 HEX HEAD BOLT 2
3A 0030018000 HEX NUT 2
3B 0040018000 WASHER, LOCK 2
3C 0041618000 WASHER, FLAT 4
4 0605000011 RUBBER SUSPENSION 2
5 0030016000 HEX NUT 4
5A 0040016000 WASHER, LOCK 4
6 0602012737 RADIATOR / INTER COOLER .........................1 ............. 0920-2216-00
7 0010116050 HEX HEAD BOLT 4
8 0030016000 HEX NUT 4
9 0040016000 WASHER, LOCK 4
10 0041216000 WASHER, FLAT 8
11 C2311101104 BRACKET, RADIATOR 2
12 0017112025 HEX HEAD BOLT 6
13 0602013260 RADIATOR PIPE ..............................................1 ............. 0981-1300-00
14 0602014820 RADIATOR PIPE ..............................................1 ............. 0981-1301-00
15 0602011500 HEX HEAD BOLT.............................................2 ............. 01010-81020
16 0602015120 RADIATOR HOSE, UPPER ENGINE...............1 ............. 4080544
17 0602015121 RADIATOR HOSE, UPPER/LOWER RAD. ......2 ............. 3283456
18 0602015122 RADIATOR HOSE, LOWER .............................1 ............. 0981-1302-00
19 0602015301 HOSE BAND ...................................................16 ............ 0980-2232-05
20 0602015123 RADIATOR HOSE ............................................1 ............. 0900-1032-00
21 0602015302 HOSE BAND ....................................................2 ............. 0980-2232-10
22 0602015410 CLAMP.............................................................1 ............. 3016478
23 0602011500 HEX HEAD BOLT.............................................1 ............. 01010-81020
24 0602014821 INTER COOLER PIPE .....................................1 ............. 0521-1097-00
25 0602013261 INTER COOLER PIPE .....................................1 ............. 0521-1098-00
26 0602015124 INTER COOLER PIPE .....................................4 ............. 3071049
27 0602015303 HOSE BAND ....................................................8 ............. 3926704
28 0602022563 ADAPTER 1
29 0602022561 90 DEGREE ELBOW 1
30 0603306590 CONNECTOR 1
31 0603300285 ROCKNUT 1
32 0605511395 VALVE 1

ENGINE AND RADIATOR ASSY. (CONTINUED)

ENGINE AND RADIATOR ASSY. (CONTINUED)
33 0603306395 HOSE JOINT 1
34 0602021070 CAP 1
35 0269200800 DRAIN HOSE 1
36 0602010220 RESERVER TANK ...........................................1 ............. 0921-1223-00
37 0602011023 CAP..................................................................1 ............. 0920-1125-00
38 813NLU0000T COOLANT LEVEL SWITCH ............................1 ............. REPLACES P/N 0602123290
39 0602011500 HEX HEAD BOLT.............................................4 ............. 01010-81020
40 0602015500 BUSHING.........................................................1 ............. S970B
41 0602013497 HOSE JOINT ...................................................1 ............. 0911-0025-00
42 0602014110 HOSE (L=250) .................................................1 ............. 0980-1310-00
43 0602013498 JOINT...............................................................1 ............. 0980-1309-00
44 0602014110 HOSE (L=325) .................................................2 ............. 0980-1310-00
45 0602014110 HOSE (L=1100) ...............................................1 ............. 0980-1310-00
46 0602015300 HOSE BAND ....................................................8 ............. 0980-2232-01
47 0193601800 HOSE 1
48 0605515106 HOSE BAND 1
49 0193601100 HOSE 1
50 0193600550 HOSE 1
51 0269501850 HOSE 1
52 0605515067 HOSE BAND 2
53 C2357300003 CLAMPER ROD 1
54 0017112025 HEX HEAD BOLT 1
55 0017116030 HEX HEAD BOLT 1
56 C2357300104 CLAMPER ROD 1
57 0017112025 HEX HEAD BOLT 2
58 0602122272 OIL PRESSURE UNIT 1
59 M9200101504 ADAPTER 1
60 0803000104 PACKING 1
61 0602123267 WATER TEMPERATURE UNIT 1
62 0602015501 ADAPTER ........................................................1 ............. 490519
63 9095720140 PACKING .........................................................1 ............. REPLACES P/N 0602021109
64 0602210189 WATER TEMPERATURE SWITCH ..................1 ............. 3408627
65 0602120481 PICK- UP TACHOMETER 1
66 4993343 ALTERNATOR 1
67 3102763 STARTER 1
68 3973114 WATER PUMP 1
69 3285324D THERMOSTATE W/O-RING 1
70 4921744 SENSOR, OIL PRESSURE 1

ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.
1 C2351101903 OPERATING PANEL 1
2 0017106020 HEX HEAD BOLT 8
3 0207006000 HEX NUT 4
4 0602101000 BATTERY SWITCH 1
5A 0030004000 HEX NUT 2
5B 0040008000 WASHER, LOCK 2
5C 0041608000 WASHER, FLAT 2
6 0601830710 ENGINE SPEED SWITCH 1
7 0601831557 EMERGENCY STOP BUTTON 1
8 0602120095 TACHOMETER 1
9 0602122093 OIL PRESSURE GAUGE 1
10 0601842450 VOLTAGE DIVIDER 1
11 0602123092 WATER TEMPERATURE GAUGE 1
12 0602121081 CHARGING AMMETER 1
13 0602125091 FUEL GAUGE 1
14 0602103090 ALARM LAMP 5
14A 0601810244 BULB, DC28V 5
15 M5483000003 SET FRAME 1
16 0017110030 HEX HEAD BOLT 2
17 0017110030 HEX HEAD BOLT 3
17A 0030010000 HEX NUT 3
17B 0040010000 WASHER, LOCK 3
17C 0041610000 WASHER, FLAT 6

OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.
1 C2231700403 SET BOARD, OUTPUT TERMINAL 1
2 C0277500004 OUTPUT TERMINAL 8
3 0801830904 HEX HEAD BOLT 8
4 0039320000 HEX NUT 16
5 0040020000 WASHER, LOCK 24
6 0041420000 WASHER, FLAT 32
7 3501860604 TERMINAL PLATE 3
8 0019110050 HEX HEAD BOLT 5
8A 0042310000 WASHER, LOCK 5
8B 0042410000 WASHER, FLAT 5
9 0601808803 CIRCUIT BREAKER, 1P 20A 2
10 0601808804 CIRCUIT BREAKER, 2P 50A 3
11 C3261600704 BRACKET, CIRCUIT BREAKER 1
11-1 0221200150 RUBBER CUSHION 1
12 0019206020 HEX HEAD BOLT 2
13 0601814013 RECEPTACLE 2
14 0601812565 RECEPTACLE, CS6369 3
15 A 0207004000 HEX NUT 10
16 C2234500104 COVER 1
17 0019206020 HEX HEAD BOLT 8
18 0601815194 TERMINAL BOARD 1
20 0601850275 GROMMET 1
21 0601851780 GROMMET 2
22 C2237102303 COVER, OUTPUT TERMINAL 1
23 0019112045 HEX HEAD BOLT 2
24 0042412000 WASHER, FLAT 4
25 0605015604 STAY RUBBER 2
26 0205012000 HEX NUT 2
27 0845043704 SPRING 2
28 C2237101204 COVER 1
29 0017108020 HEX HEAD BOLT 7
30 C2237102403 COVER, OUTPUT TERMINAL 1
31 0019210030 HEX HEAD BOLT 2
32 0845054204 COLLAR 2
33 0805015604 STAY RUBBER 1
34 C2237101504 COVER 1
35 C2237500104 BRACKET 1
36 0017106020 HEX HEAD BOLT 2

BATTERY ASSY.

BATTERY ASSY.
1 0165614551 BATTERY 2 145G51
2 C9109100604 BATTERY SHEET 2
3 3972250004 BATTERY BAND 1
4 0805002904 BATTERY BOLT 2
5 0037808000 WING NUT 2
6 0040008000 WASHER, LOCK 2
7 0041608000 WASHER, FLAT 2
8 C2346600404 BATTERY CABLE 1
12 C2346200004 EARTH CABLE 2
13 0347010030 HEX HEAD BOLT 4
14 0208110000 HEX NUT 4
15 0845040414 TERMINAL CAP (+) 2
16 0845041304 TERMINAL CAP (-) 2
17 0017116030 HEX HEAD BOLT 1
18 0040516000 TOOTHED WASHER 1
19 0017112025 HEX HEAD BOLT 1
20 0040512000 TOOTHED WASHER 1

MUFFLER ASSY.

MUFFLER ASSY.
1 C2331100002 MUFFLER 1
2 0019210025 HEX HEAD BOLT 4
3 M5333000003 EXHAUST PIPE 1
4 0602325066 BEND BOLT CLAMP 1
5 C1334200304 GASKET 1
6 0010312055 HEX HEAD BOLT 4
6A 0030312000 HEX NUT 4
6B 0042512000 WASHER, LOCK 4
6C 0041612000 WASHER, FLAT 8
7 C2331300004 COVER 2
8 0017108020 HEX HEAD BOLT 4

FUEL TANK ASSY.

FUEL TANK ASSY.
1 C2363000303 FUEL TANK 1
1-1 0810105004 CAP, FUEL TANK 1
1-2 0810105400 FUEL FILTER 1
1-3 0264100525 HOSE, FUEL GAUGE 1
1-4 0605515079 HOSE BAND 2
2 0605503023 FUEL SESOR 1
3 0802120604 PACKING 1
4 0605501093 UNIT, FUEL 1
5 0605516090 PACKING 1
7 8195523104 TANK BAND 2
8 0805003414 PAD, TANK BAND 4
9 0017108020 HEX HEAD BOLT 4
10 0207308000 SUPER LOCK NUT 2
11 0222100300 TANK SHEET 6
12 0130206000 STREET ELBOW, 1/2" 1
13 0134306170 DRAIN PIPE 1
14 0603325026 VALVE 1
15 0132006000 PLUG, 1/2" 1
16 C1367700304 LOCK PLATE 1
17 0019208020 HEX HEAD BOLT 2
18 0845039604 RUBBER SEAL 1
19 0191503400 SUCTION HOSE 1
20 0191503700 RETURN HOSE 1
21 0605515073 HOSE BAND 4

ENCLOSURE ASSY.

ENCLOSURE ASSY.
1 C2413003202 BASE 1
2 C3414100104 FLOOR PANEL 1
3 C2414100004 FLOOR PANEL 1
4 0019208020 HEX HEAD BOLT 14
5 C2414600304 DUCT 1
5A C2494000304 ACOUSTIC SHEET 1
6 0017108020 HEX HEAD BOLT 4
7 M5423000002 FRONT FRAME 1
7A M5493100003 ACOUSTIC SHEET 1
8 M5423000102 FRONT FRAME 1
9 0017108020 HEX HEAD BOLT 10
10 0019210025 HEX HEAD BOLT 8
11 C2424200003 COVER, FRONT FRAME 1
12 C2424201504 COVER, FRONT FRAME 1
13 0019208020 HEX HEAD BOLT 23
14 0845042703 FILLER BRACKET 1
15 0019208020 HEX HEAD BOLT 4
16 M5433000002 CENTER FRAME 1
17 0010114050 HEX HEAD BOLT 4
17A 0030014000 HEX NUT 4
17B 0040014000 WASHER, LOCK 4
17C 0041214000 WASHER, FLAT 8
18 0010114040 HEX HEAD BOLT 8
18A 0030014000 HEX NUT 8
18B 0040014000 WASHER, LOCK 8
18C 0041214000 WASHER, FLAT 16
19 C2367700404 COVER 1
20 0019208020 HEX HEAD BOLT 2
21 M5443000002 REAR FRAME 1
22 0019210025 HEX HEAD BOLT 4
23 M5443300003 COVER, REAR FRAME 1
24 M5443300104 PANEL 1
25 0207008000 HEX NUT 12
26 0019208020 HEX HEAD BOLT 14
27 M5453000003 DOOR, REAR FRAME 1
28 M5453000103 DOOR, REAR FRAME 1
29 8225147004 WINDOW PLATE 2
30 0207306000 SELF- LOCKING U NUT 12
31 B9114000102 DOOR HANDLE 1
32A 0030006000 HEX NUT 4

ENCLOSURE ASSY. (CONTINUED)

33 C3444700004 DOOR ROD 1
34 8195146304 DOOR ROD 1
35 0845050704 STAY 4
36 0207006000 HEX NUT 8
37 0805011304 STOPPER, DOOR 1
38 0805011204 STOPPER, DOOR 1
39 0207006000 HEX NUT 4
40 0845047104 HINGE 2
40A 0845045004 WASHER 2
41 0845047204 HINGE 2
41A 0845045004 WASHER 2
42 0019208020 HEX HEAD BOLT 6
43 0601850097 STOPPER 2
45 0845031504 CAP 4
46 0600800320 MANUAL PAK 1
47 0207006000 HEX NUT 4
48 M5463100002 ROOF PANEL 1
49 M3310600004 COVER 1
50 0019208020 HEX HEAD BOLT 4
51 C2464200502 ROOF PANEL 1
52 M5423200103 COVER, FRONT FRAME 1
53 0019208020 HEX HEAD BOLT 41
54 M5453200002 SPLASHER PANEL 1
55 0019208065 HEX HEAD BOLT 6
56 M5453000203 SIDE PANEL 1
57 M5453000303 SIDE PANEL 1
58 M5453000803 SIDE PANEL 1
59 M5453000903 SIDE PANEL 1
60 M5453300004 DUCT 1
61 M5453300104 DUCT 1
62 M5453300904 DUCT 2
63 M5453300204 DUCT 1
64 0207008000 HEX NUT 35
65 B9114000002 DOOR HANDLE 4


66 0825007362 DOOR HANDLE 3
67A 0030006000 HEX NUT 16
68 0845046904 HINGE 5
68A 0845045004 WASHER 5
69 084504700 HINGE 6
69A 0845045004 WASHER 6
70 0019208020 HEX HEAD BOLT 25
71 0601850097 STOPPER 8
73 0845031504 CAP 11
74 M5463500004 GUTTER 2
75 C2464500304 GUTTER 2
76 0019208020 HEX HEAD BOLT 4

RUBBER SEALS ASSY.

RUBBER SEALS ASSY.
1 0229201400 SEAL RUBBER 4
2 0228901015 SEAL RUBBER 4
3 0228901250 SEAL RUBBER 3
4 0228901310 SEAL RUBBER 3
5 0228900650 SEAL RUBBER 4
6 0228900650 SEAL RUBBER 1
7 0228900710 SEAL RUBBER 1
8 0229201300 SEAL RUBBER 1
9 0221200705 SEAL RUBBER 2
10 0228801210 SEAL RUBBER 2
11 0228100510 SEAL RUBBER 4
12 0228100120 SEAL RUBBER 4
13 0229200470 SEAL RUBBER 2
14 0229201130 SEAL RUBBER 1

NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.
1-1 C3550000703 DECAL : HANDLING PROCEDURES .........................1 ................. C3500 0070
1-2 C9522100003 DECAL : CAUTION ......................................................2 ................. C9221 0000
CONTROL BOX GROUP

2-1 0800520100 PLATE : ON - OFF........................................................1 ................. AT-202
2-2 0800520904 PLATE : AMMETER CHANGE- OVER SWITCH..........1 ................. N-2438
2-3 0800520814 PLATE : VOLTMETER CHANGE- OVER SWITCH ......1 ................. N-2439
2-4 0840624504 DECAL : CIRCUIT BREAKER .....................................1 ................. S-3031
2-5 0840624604 DECAL : PANEL LIGHT SWITCH ................................1 ................. S-3032
2-6 0840624704 DECAL : PILOT LAMP .................................................1 ................. S-3033
2-7 0840624804 DECAL : VOLTAGE REGULATOR ................................1 ................. S-3034
2-8 B9531100604 DECAL : WARNING ELECTRIC SHOCK HAZARD .....1 ................. B9311 0060
2-9 C0551000903 DECAL : SETTING FOR OUTPUT VOLTAGE..............1 ................. C0510 0090
2-10 C2551000004 DECAL : SAFETY INSTRUCTIONS ............................1 ................. C2510 0000
2-11 M5560100903 DECAL : WHISPERWATT 300 .....................................1 ................. M5601 0090A
2-12 C9502400004 DECAL : HIGH IDLE SPEED .......................................1 ................. C9024 0000
2-13 C9520027704 DECAL : DIAGNOSTIC BUTTON ................................1 ................. C9200 2770
2-14 C9520028604 DECAL : WARNING DIAGNOSTIC LAMP ...................1 ................. C9200 2860
2-15 C9520028704 DECAL : SHUTDOWN DIAGNOSTIC LAMP ...............1 ................. C9200 2870
2-16 C9520028804 DECAL : LOW IDLE SPEED / DIAG. CODE SW..........1 ................. C9200 2880
2-17 C9521007504 DECAL : DIAGNOSTIC SWITCH .................................1 ................. C9210 0750
2-18 Z0110001504 DECAL : RESET ..........................................................1 ................. Z0100 0150
ENGINE & RADIATOR GROUP

3-1 6360610304 DECAL : WATER ..........................................................1 ................. S-1880
3-2 6360620204 DECAL : OIL DRAIN PLUG .........................................1 ................. S-1885
3-3 B9504000404 DECAL : MOVING PARTS ...........................................2 ................. B9040 0040
3-4 B9504100104 DECAL : WARNING HOT COOLANT ..........................1 ................. B9041 0010
ENGINE OPERATING PANEL GROUP

4-1 C0551000504 DECAL : BATTERY SWITCH .......................................1 ................. C0510 0050
4-2 C3550000404 DECAL : ALARM LAMP ...............................................1 ................. C3500 0040
4-3 M5550000503 DECAL : OPERATING PANEL .....................................1 ................. M5500 0050
OUTPUT TERMINAL GROUP

5-1 0840614104 DECAL : GROUND ......................................................1 ................. S-2635
5-2 0840619904 DECAL : DANGER HIGH VOLTAGE ............................1 ................. S-2731
5-3 9039209064 DECAL : START CONTACT .........................................1 ................. S-4468
5-4 B9511100304 DECAL : WARNING .....................................................1 ................. B9111 0030
5-7 C0551000404 DECAL : 3- PHASE OUTPUT TERMINAL ...................1 ................. C0510 0040
5-8 C1551000803 DECAL : RECEPTACLE & CIRCUIT BREAKER..........1 ................. C1510 0080

NAMEPLATE AND DECALS ASSY. (CONTINUED)

NAMEPLATE AND DECALS ASSY. (CONTINUED)
BATTERY GROUP
6-1 0800689404 DECAL : + ............................................................... 1 ...................... S-2090
6-2 0800689504 DECAL : - ................................................................ 1 ...................... S-2091
6-3 C9505300004 DECAL : CAUTION ................................................. 1 ...................... C9053 0000
MUFFLER GROUP
7-1 A9504000014 DECAL : DANGER ........................................................................... A9040 0001
7-2 B9504200004 DECAL : WARNING ENGINE EXHAUST................ 1 ...................... B9042 0000
FUEL TANK GROUP

8-1 1320620904 DECAL : DIESEL FUEL .......................................... 1 ...................... S-1756
8-2 6360620004 DECAL : FUEL DRAIN PLUG ................................. 1 ...................... S-1883
8-3 B9504500004 DECAL : WARNING DIESEL FUEL ........................ 1 ...................... B9045 0000
BONNET GROUP
9-1 1320610603 DECAL : WATER - OIL ........................................... 1 ...................... S-1760
9-2 1320621504 DECAL : SUPPORT HOOK .................................... 2 ...................... S-2257
9-3 0840625902 DECAL : MQ ........................................................... 1 ...................... S-3057
9-4 B9504000304 DECAL : CAUTION HOT PARTS ............................ 1 ...................... B9040 0030
9-5 B9531100604 DECAL : WARNING ELECTRIC SHOCK HAZARD 1 ...................... B9311 0060
9-6 0600500090 EMBLEM ................................................................. 2
9-6 A 0021106016 MACHINE SCREW ................................................. 4
9-7 M5560101503 STRIPE ................................................................... 1
9-8 M5560101303 STRIPE ................................................................... 1
9-9 M5560101103 STRIPE ................................................................... 1
9-10 M5560101004 STRIPE ................................................................... 4
9-11 M5560101403 STRIPE ................................................................... 1
9-12 M5560101203 STRIPE ................................................................... 1
9-13 C9504000304 DECAL : CAUTION ................................................. 1 ...................... C9040 0030
9-14 M9504200004 DECAL : WARNING START FIRES ........................ 1 ...................... M9042 0000

TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS 5. Parts must be in new and resalable Multiquip reserves the right to quote and
Terms of payment for parts are net 30 days. condition, in the original Multiquip sell direct to Government agencies, and to
package (if any), and with Multiquip part Original Equipment Manufacturer accounts
FREIGHT POLICY numbers clearly marked. who use our products as integral parts of their
6. The following items are not returnable: own products.
All parts orders will be shipped collect or
prepaid with the charges added to the invoice. a. Obsolete parts. (If an item is in the SPECIAL EXPEDITING SERVICE
All shipments are F.O.B. point of origin. price book and shows as being
Multiquip’s responsibility ceases when a A $35.00 surcharge will be added to the
replaced by another item, it is
signed manifest has been obtained from the invoice for special handling including bus
obsolete.)
carrier, and any claim for shortage or damage shipments, insured parcel post or in cases
b. Any parts with a limited shelf life where Multiquip must personally deliver the
must be settled between the consignee and
(such as gaskets, seals, “O” rings, parts to the carrier.
the carrier.
and other rubber parts) that were
MINIMUM ORDER purchased more than six months LIMITATIONS OF SELLER’S LIABILITY
prior to the return date. Multiquip shall not be liable hereunder for
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for c. Any line item with an extended damages in excess of the purchase price of
instructions regarding handling of orders not dealer net price of less than the item with respect to which damages are
meeting this requirement. $5.00. claimed, and in no event shall Multiquip be
d. Special order items. liable for loss of profit or good will or for any
RETURNED GOODS POLICY other special, consequential or incidental
e. Electrical components. damages.
Return shipments will be accepted and
credit will be allowed, subject to the following f. Paint, chemicals, and lubricants.
LIMITATION OF WARRANTIES
provisions: g. Decals and paper products.
No warranties, express or implied, are
1. A Returned Material Authorization h. Items purchased in kits. made in connection with the sale of parts or
must be approved by Multiquip prior to 7. The sender will be notified of any material trade accessories nor as to any engine not
shipment. received that is not acceptable. manufactured by Multiquip. Such warranties
2. To obtain a Return Material Authorization, 8. Such material will be held for five made in connection with the sale of new,
a list must be provided to Multiquip working days from notification, pending complete units are made exclusively by a
Parts Sales that defines item numbers, instructions. If a reply is not received statement of warranty packaged with such
quantities, and descriptions of the items within five days, the material will be units, and Multiquip neither assumes nor
to be returned. returned to the sender at his expense. authorizes any person to assume for it
any other obligation or liability whatever in
a. The parts numbers and descriptions 9. Credit on returned parts will be issued
connection with the sale of its products. Apart
must match the current parts price at dealer net price at time of the original
from such written statement of warranty,
list. purchase, less a 15% restocking
there are no warranties, express, implied or
b. The list must be typed or computer charge.
statutory, which extend beyond the description
generated. 10. In cases where an item is accepted, for of the products on the face hereof.
c. The list must state the reason(s) which the original purchase document
for the return. can not be determined, the price will be
based on the list price that was effective Effective: February 22, 2006
d. The list must reference the sales twelve months prior to the RMA date.
order(s) or invoice (s) under
which the items were originally 11. Credit issued will be applied to future
purchased. purchases only.
e. The list must include the name PRICING AND REBATES
and phone number of the person Prices are subject to change without prior
requesting the RMA. notice. Price changes are effective on a
3. A copy of the Return Material Authorization specific date and all orders received on or
must accompany the return shipment. after that date will be billed at the revised price.
Rebates for price declines and added charges
4. Freight is at the sender’s expense. All for price increases will not be made for stock
parts must be returned freight prepaid to on hand at the time of any price change.
Multiquip’s designated receiving point.

NOTES

OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600 Fax (972) 315-1847
Lewisville, TX 75057
Contact: [email protected]
Web: www.mqpower.com
MQ Parts Department
800-427-1244 Fax: 800-672-7877
310-537-3700 Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2009, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and 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.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is: DENYO CO., LTD, JAPAN

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OPERATION AND PARTS MANUAL

PARTS LIST NO. C2870300204

To find the latest revision of this

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Diesel engine exhaust and some of

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Order via Phone: Domestic (US) Dealers Call:

When ordering parts, please supply:

All orders are treated as Standard Orders and will

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 5

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DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 13

Figure 2. Typical Generator Grounding Application

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Table 4. Generator Major Components

Figure 3. Major Components

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 17

Figure 4. Generator Control Panel

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Located behind the generator control panel is the

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 19

AIR FILTER COOLANT LEVEL

Figure 5. Engine Operating Panel

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DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 21

Figure 6. Output Terminal Panel

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

Twist Lock Dual Voltage 120/240 VAC Receptacles

Figure 8. 120/240V Twist-Lock Auxiliary

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 23

Figure 11. Over Current Relay

Figure 10. Connecting Loads

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DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 25

Three Phase 480 Volt 361 amps

Figure 12. Voltage Change-Over Board

Table 7. Voltages Available

PAGE 26 — DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09)

Figure 13. Voltage Change-Over Board

AC Voltmeter Gauge Reading

Figure 14. AC Voltmeter Figure 15. AC Voltmeter Gauge

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 27

Figure 21. UVWO Terminal Lugs 1Ø-240V