CUMMINS QSL9-G3 Diesel Engine MASTER Parts Manual

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES. To ﬁnd the latest revision of this publication, visit our website at: www.mqpower.com WHISPERWATT™ SERIES MODEL DCA300SSC 60HZ GENERATOR (CUMMINS QSL9-G3 DIESEL ENGINE) PARTS LIST NO. C2870300204 Revision #0 (06/25/09) OPERATION AND PARTS MANUAL

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

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 3 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. REPORTING SAFETY DEFECTS

— DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) TABLE OF CONTENTS DCA300SSC 60 Hz Generator Proposition 65 warning ............................................ 2 Reporting Safety Defects......................................... 3 Table of Contents..................................................... 4 Parts Ordering Procedures ...................................... 5 Safety Information .............................................. 6-11 Speciﬁcations ........................................................ 12 Dimensions ............................................................ 13 Installation ........................................................ 14-15 General Information ............................................... 16 Major Components ................................................ 17 Generator Control Panel ................................... 18-19 Engine Operating Panel.................................... 20-21 Output Terminal Panel Familiarization .............. 22-24 Load Application .................................................... 25 Generator Outputs ................................................. 26 Generator Outputs/Gauge Reading....................... 27 Output Terminal Panel Connections ................. 28-29 Inspection/Setup ............................................... 30-33 Genertor Start-Up Procedure (Manual) ............ 34-35 Generator Start-Up Procedure (Auto Mode).......... 36 Generator Shut-Down Procedures ........................ 37 Maintenance ..................................................... 38-41 Trailer Maintenance .......................................... 42-45 Trailer Wiring Diagram ........................................... 46 Generator Wiring Diagram ..................................... 47 Engine Wiring Diagram .......................................... 48 Controller Wiring Diagram ..................................... 49 Troubleshooting (Generator) .................................. 50 Troubleshooting (Engine Controller) ...................... 51 Troubleshooting (Diagnostic lamp) ........................ 52 Explanation of Code in Remarks Column.............. 54 Suggested Spare Parts ......................................... 55 Component Drawings Generator Assembly ......................................... 56-59 Control Box Assembly ....................................... 60-63 Engine and Radiator Assembly ......................... 64-67 Engine Operating Panel Assembly . ................... 68-69 Output Terminal Assembly ............................... 70-71 Battery Assembly.............................................. 72-73 Mufﬂer Assembly . .............................................. 74-75 Fuel Tank Assembly . ......................................... 76-77 Enclosure Assembly ......................................... 78-83 Rubber Seals Assembly ................................... 84-85 Nameplate and Decals Assembly..................... 86-89 Terms and Conditions of Sale — Parts ................. 90

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 5 PARTS ORDERING PROCEDURES www.mqpower.com Ordering parts has never been easier! Choose from three easy options: WE ACCEPT ALL MAJOR CREDIT CARDS! When ordering parts, please supply: ❒ Dealer Account Number ❒ Dealer Name and Address ❒ Shipping Address (if different than billing address) ❒ Return Fax Number ❒ Applicable Model Number ❒ Quantity, Part Number and Description of Each Part ❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL ■ Priority One ✓ Truck ■ Ground ■ Next Day ■ Second/Third Day If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip. com. To obtain an MQ Account, contact your District Sales Manager for more information. Order via Internet (Dealers Only): Order parts on-line using Multiquip’s SmartEquip website! ■ View Parts Diagrams ■ Order Parts ■ Print Speciﬁcation Information Note: Discounts Are Subject To Change Goto www.multiquip.com and click on Order Parts to log in and save! Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.* Order via Fax (Dealers Only): All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877) Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.* Order via Phone: Domestic (US) Dealers Call: 1-800-427-1244 Best Deal! International Customers should contact their local Multiquip Representatives for Parts Ordering information. Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you. Note: Discounts Are Subject To Change Effective: January 1 st , 2006 NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST.

— DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) SAFETY INFORMATION Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others. SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages 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 Indicates a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS INJURY. CAUTION Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. NOTICE Addresses practices not related to personal injury. Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 7 SAFETY INFORMATION GENERAL SAFETY CAUTION NEVER  operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations. NEVER  operate this equipment when not feeling well due to fatigue, illness or when under medication. NEVER  operate this equipment under the influence of drugs or alcohol. ALWAYS  check the equipment for loosened threads or bolts before starting. DO NOT  use the equipment for any purpose other than its intended purposes or applications. NOTICE This equipment should only be operated by trained and  qualified personnel 18 years of age and older. Whenever necessary, replace nameplate, operation and  safety decals when they become difficult read. Manufacturer does not assume responsibility for any  accident due to equipment modifications. Unauthorized equipment modification will void all warranties. NEVER  use accessories or attachments that are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result. ALWAYS  know the location of the nearest fire extinguisher. 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 fire department. This information will be invaluable in the case of an emergency. GENERATOR SAFETY DANGER NEVER  operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death. WARNING NEVER  disconnect any emergency or safety devices. These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties. CAUTION NEVER  lubricate components or attempt service on a running machine. NOTICE ALWAYS  ensure generator is on level ground before use. ALWAYS  keep the machine in proper running condition. Fix damage to machine and replace any broken parts  immediately. ALWAYS  store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel

— DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) SAFETY INFORMATION ENGINE SAFETY DANGER The engine fuel exhaust gases contain poisonous carbon  monoxide. This gas is colorless and odorless, and can cause death if inhaled. The engine of this equipment  requires an adequate free flow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine. WARNING DO NOT  place hands or fingers inside engine compartment when engine is running. NEVER  operate the engine with heat shields or guards removed. Keep fingers, hands hair and clothing away  from all moving parts to prevent injury. DO NOT  remove the radiator cap while the engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator. DO NOT  remove the coolant drain plug while the engine is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator. DO NOT  remove the engine oil drain plug while the engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator. CAUTION NEVER  touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing equipment. NOTICE NEVER  run engine without an air filter or with a dirty air filter. Severe engine damage may occur. Service air filter frequently to prevent engine malfunction. NEVER  tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable. Wet stacking is a common problem with diesel engines  which are operated for extended periods with light or no load applied. When a diesel engine operates without sufficient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance. In order for a diesel engine to operate at peak efficiency, it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel. Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel. State Health Safety Codes and Public Resources  Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) — PAGE 9 SAFETY INFORMATION FUEL SAFETY DANGER DO NOT  start the engine near spilled fuel or combustible fluids. Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited. ALWAYS  refuel in a well-ventilated area, away from sparks and open flames. ALWAYS  use extreme caution when working with flammable liquids. DO NOT  fill the fuel tank while the engine is running or hot. DO NOT  overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in appropriate containers, in well-ventilated  areas and away from sparks and flames. NEVER  use fuel as a cleaning agent. DO NOT  smoke around or near the equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine. TOWING SAFETY CAUTION Check with your local county or state safety  towing regulations, in addition to meeting Department of Transportation (DOT) Safety Towing Regulations, before towing your generator. Refer to MQ Power trailer manual for additional safety  information. In order to reduce the possibility of an accident while  transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.  ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle  are rated equal to, or greater than the trailer “gross vehicle weight rating.” ALWAYS  inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains, etc. Check the tire air pressure on both towing vehicle and  trailer. Trailer tires should be inflated to 50 psi cold. Also check the tire tread wear on both vehicles. ALWAYS  make sure the trailer is equipped with a safety chain. ALWAYS  properly attach trailer’s safety chains to towing vehicle. ALWAYS  make sure the vehicle and trailer directional, backup, brake and trailer lights are connected and working properly. DOT Requirements include the following:  • Connect and test electric brake operation. • Secure portable power cables in cable tray with tie wraps. The maximum speed for highway towing is  55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain. Avoid sudden stops and starts. This can cause skidding,  or jack-knifing. Smooth, gradual starts and stops will improve towing. Avoid sharp turns to prevent rolling.  Trailer should be adjusted to a level position at all times  when towing. Raise and lock trailer wheel stand in up position when  towing. Place  chock blocks underneath wheel to prevent rolling while parked. Place  support blocks underneath the trailer’s bumper to prevent tipping while parked. Use the trailer’s swivel jack to adjust the trailer height to  a level position while parked.

— DCA300SSC GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/25/09) SAFETY INFORMATION ELECTRICAL SAFETY DANGER DO NOT  touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn. The electrical voltage required to  operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals. NEVER  insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death. Backfeed to a utility system can cause  electrocution and/or property damage. NEVER connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious injury or even death. Power Cord/Cable Safety DANGER NEVER  let power cords or cables lay in water. NEVER stand in water  while AC power from the generator is being transferred to a load. NEVER  use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation. NEVER  grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death. Make sure power cables are securely connected to the  generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator. NOTICE ALWAYS  make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual. Grounding Safety DANGER ALWAYS  make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death by electrocution can result from operating an ungrounded generator. NEVER  use gas piping as an electrical ground.

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CUMMINS QSL9-G3 Diesel Engine MASTER Parts Manual

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