MQ Power DCA300SSK Generator Operation And Parts Manual

OPERATION AND PARTS MANUAL

WHISPERWATT TM SERIES

MODELS:

DCA-300SSK

DCA-300SSK2

DCA-300SSK3

60 Hz GENERATORS

PARTS LIST NO. C2871300704

SERIAL NO. 3708297~

Revision #4 (03/27/06)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

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

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave.

800-421-1244

Carson, CA 90746

Email: [email protected]

FAX: 310-632-2656

Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284

SERVICE DEPARTMENT

800-835-2551

310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

FAX: 310-638-8046

© COPYRIGHT 2006, MULTIQUIP INC.

MQ Power Inc, Ultra-Silent series, 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 thier 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 are based on the DCA-300SSK SERIES WHISPERWATT AC Generators. 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.

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 3

TABLE OF CONTENTS

California Proposition 65 Warning ..................................... 2

Here's How To Get Help .................................................... 3

Table Of Contents ............................................................. 4

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMPONENT DRA WINGS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Name Plate and Decals ......................................... 114-119

Terms and Condition of Sale — Parts .......................... 120

NOTE

Specification and part number are subject to change without notice

.


PARTS ORDERING PROCEDURES

❒

❒

When ordering parts, please supply the following information:

❒

❒ Quantity, part number and description of each part

❒ Specify preferred method of shipment:

✓FedEx or UPS Ground

Note: Unless otherwise indicated by customer, all

✓FedEx or UPS Second Day or Third Day orders are treated as “Standard Orders”, and will

✓FedEx or UPS Next Day ship within 24 hours. We will make every effort to

✓Federal Express Priority One

✓DHL

✓Truck ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock

Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave.

800-421-1244

Carson, CA 90746

Email: [email protected]

FAX: 310-632-2656

Internet: www.mqpower.com


800-427-1244

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284


800-835-2551

310-537-3700


800-835-2551


800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

FAX: 310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered via

Fax

Standard orders

3%

Web 5%

Special freight allowances when you order 10 or more line items via Web or Fax!**

Stock orders

($750 list and above)

10%

10%

FedEx Ground Service at no charge for freight

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-632-2656

E-MAIL: [email protected]

INTERNET: www.mqpower.com

Direct TOLL-FREE access to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)


D e s i g n

N o .

o f P o l e s

E x c ti a it o n

S t a n d b y O u t p u t

P r i m e O u t p u t

G e n e r a t o r R P M

V o tl a g e

V o tl a g e

—

—

3

1

Ø

Ø

A r m a t u r e C o n n e c it o n

V o

( N o tl a g e l o a d

R e g u l a t o f u ll it o n l o a d )

P o w e r F a c t o r

F r e q u e n c y

F r e q u e n c y

N o l o a d t o

R e g u l a f u ll l o a it o d n :

F r e q u e n c y

S t e a d y

R e g u l a

S t a t e it o n :

I n s u l a it o n

S o

F u ll u n l o d a

L e v e l d a t d B ( A )

2 3 f e e t

D i m e n s i o n s

( L x W x

A p p r o x .

H )

D r y N e t W e i g h t

DCA-300SSK SERIES — SPECIFICATIONS

T a b l e 1 .

G e n e r a t o r S p e c i f i c a t i o n s

R e v o l v i n g if e l d , S e

D r i p p r o o f S i n g l e fl v e n t li a t e d b e a r i n g

4 p o l e

B r u s h l e s s w ti h A V R

2 6 4

2 4 0

K

K

W

W

(

(

3

3

3

0

1 8 0 0

0

0

K V A )

K V A )

2 0 8 , 2 2 0 , 2 4 0 , 4 1 6 , 4 4 0 , 4 8 0 V R e c o n n e c t a b l e

1 2 0 , 1 2 7 , 1 3 9 , 2 4 0 , 2 5 4 , 2 7 7 V A d j u s t a b l e

S t a r w ti h n e u t r a l

± 1 .

5 %

0 .

8

6 0 H z

I s o c h r o n o u s u n d e r v a r y i n g l o a d s f r o m n o l o a d t o 1 0 0 % r a t e d l o a d

+ 0 .

2 5 % o f m e a n v a l u e f o r c o n s t a n t l o a d s f r o m n o l o a d t o f u ll l o a d

C l a s s F

7 1

1 5 3 x 5 6 x 7 1 i n .

( 3 8 9 x 1 4 2 x 1 8 0 m m .

)

9 , 1 7 2 l b s .

( 4 , 1 6 0 k g .

)

M o d e l

T y p e

N o .

o f C y l i n d e r s

B o r e x S t r o k e

R a t e d O u t p u t

D i s p l a c e m e n t

S t a r t i n g

C o o l a n t C a p a c i t y

L u b e O i l C a p a c i t y

F u e l C o n s u m p t i o n

B a t t e r y

F u e l

T a b l e 2 .

E n g i n e S p e c i f i c a t i o n s

K O M A T S U S A 6 D 1 2 5 E 2

4 i n j e c

C y c l e , it o n , t u w r b a t e r c o o l e o c h a r g e d d , w d ti h i r e c a f t t e r c o o l e r

K O M A T S U S A A 6 D 1 2 5 E 2

4 C y t u r b o c c l e h a

, r w a t e r g e d w ti c o o h a l e i r d , t o d i r e c t a i r a f i n j t e r e c it o n , c o o l e r

6 c y il n d e r s

4 .

9 i n .

x 5 .

9 i n .

( 1 2 5 m m x 1 5 0 m m )

3 4 5 h p / 1 8 0 0 r p m 3 5 4 h p / 1 8 0 0 r p m

8 .

5 g a .l

( 3 2 .

6 l ti e r s )

6 7 3 c u .

i n .

( 1 1 , 0 4 0 c c )

E l e c t r i c

9 .

8 g a .l

( 3 7 l ti e r s )

1 6 .

1 g a .l

( 6 0 l ti e r s )

1 7 .

5 g a .l

( 6 6 .

5 L ) / h r a t f u l l l o a d 1 6 .

7 g a .l

( 6 3 .

2 L ) / h r a t f u l l l o a d

1 2 V 1 5 0 A H x 2

# 2 D i e s e l F u e l

1 6 .

4 g a .l

( 6 2 l ti e r s )


DCA-300SSK SERIES — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

R e f e r e n c e

L e t t e r

A

B

C

D

E

T A B L E 3 .

D I M E N S I O N S

D i m e n s i o n i n .

( m m ).

R e f e r e n c e L e t t e r D i m e n s i o n i n .

( m m ).

4 2 .

3 2 i n .

( 1 , 0 7 5 m m ).

3 9 .

9 6 i n .

( 1 , 0 1 5 m m ).

2 5 .

2 0 i n .

( 6 4 0 m m ).

2 3 .

0 3 i n .

( 5 8 5 m m ).

3 9 .

9 6 i n .

( 1 , 0 1 5 m m ).

I

H

F

G

4 2 .

3 2 i n .

( 1 , 0 7 5 m m ).

1 4 7 .

6 4 i n .

( 3 , 7 5 0 m m ).

7 0 .

9 8 i n .

( 1 , 8 0 0 m m ).

5 5 .

1 2 i n .

( 1 , 4 0 0 m m ).


DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the

Safety Messages and Operating Instructions could result in injury to yourself and others.

NOTE

This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the

MQ Power Model DCA-400SSVU

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " Hazard Symbols" which appear throughout this manual, and will be referenced in conjunction with Safety " Message Alert Symbols".

WARNING - LETHAL EXHAUST GASES

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The

Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

WARNING - EXPLOSIVE FUEL

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

DO NOT fill the fuel tank while the engine is running or hot.

DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!


DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers, or guards removed. Keep fingers, hands,

hair and clothing away from all moving parts to prevent injury.

CAUTION - RESPIRATORY HAZARDS

ALWAYS wear approved respiratory protection.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - SIGHT AND HEARING HAZARDS

ALWAYS wear approved eye and

hearing protection.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings of the engine governor or settings.

Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.


DCA-300SSK SERIES — RULES FOR SAFE OPERATION

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury or even DEATH! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-400SSVU Whisperwatt™ AC Generator.

General Safety:

■ DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■ This equipment should not be operated by persons under

18 years of age.

■ NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■ NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■ NEVER operate this equipment under the influence or drugs or alcohol.

■ ALWAYS check the machine for loosened threads or bolts before starting.

■ NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death.

■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■ High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot! components can cause serious burns.

■ The engine of this generator requires an adequate free flow of cooling air. NEVER operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

■ DO NOT place hands or fingers inside generator engine compartment when engine is running.

■ NEVER run engine without air filter. Severe engine damage may occur.

■ DO NOT leave the generator running in the manual mode unattended.

■ Refer to the VOLVO Engine Owner's Manual for engine technical questions or information.

■ ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■ NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■ Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■ Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.


DCA-300SSK SERIES — RULES FOR SAFE OPERATION

Generator Grounding

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

Article 250 (Grounding) of the National Electrical Code

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

The following safety recommendations should also be followed:

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

■ ALWAYS make sure that electrical circuits are properly

grounded 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.

■ ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

Electrical Safety

■ ALWAYS have a qualified electrician perform the generator wiring installation.

■ ALWAYS make sure generator installation is accordance with the National Electrical Code (NEC) and local codes before operating generator.

■ NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■ NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■ ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generator is being transfer to a load.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator WET

HANDS and electrical shock.

NEVER grab or touch a live power cord with wet hands.

POWER

CORD

(POWER ON)

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

Backfeed to a utility system can cause electrocution and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened.

ALWAYS have a licensed electrician perform the installation


DCA-400SSVU — RULES FOR SAFE OPERATION

Maintenance Safety

■ The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits.

Turn all circuit breakers OFF before performing maintenance on the generator.

■ NEVER lubricate components or attempt service on a running machine.

■ ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.

■ Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■ ALWAYS allow the machine a proper amount of time to cool before servicing.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and always replace broken parts.

■ ALWAYS service air cleaner frequently to prevent engine malfunction.

Battery Safety

Use the following guidelines when handling the battery:

■ The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses.

■ Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid severe injury or DEATH: is the possibility of risk that the battery may explode.

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids.

If these gases and liquids come in contact with a flame or spark, an explosion could occur.


To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations.

Always allow sufficient time for the engine and generator to cool before performing maintenance.

■ Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■ Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

■ Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

charged a buildup of combustible gas will occur.

working condition. Repair or replace all worn cables.

environment, to avoid risk of a dangerous concentration of combustible gases.

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

contact with your EYES, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.


DCA-400SSVU — RULES FOR SAFE OPERATION

Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting Department of

Transportation (DOT) Safety Towing Regulations, before towing your generator.

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed Towing & Transporting Safety guidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■ ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■ 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 attach trailer’s safety chains to towing vehicle properly.

■ ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■ DOT Requirements include the following: z Connect and test electric brake operation.

z 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.

■ Place chock blocks underneath wheel to prevent rolling, while parked.

■ Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■ Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all times when towing.

■ Raise and lock trailer wheel stand in up position when transporting.

■ The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■ Place support blocks underneath the trailer’s bumper to prevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Emergencies

■ ALWAYS know the location of the nearest fire extinguisher.

■ ALWAYS know the location of the nearest and first aid kit.

■ ALWAYS know the location of the nearest phone or keep a phone on

the job site, in case of emergencies.

■ ALWAYS have easy access to the phone numbers of the nearest Ambulance, Doctor and Fire Department. This information will be invaluable in the case of an emergency.


DCA-300SSK SERIES — GENERATOR DECALS

The DCA-300SSK generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

Figure 2. Generator Decals


DCA-300SSK SERIES — GENERATOR DECALS

Figure 3. Generator Decals


DCA-300SSK SERIES — INSTALLATION

Figure 4. Typical Generator Grounding Application


DCA-300SSK SERIES — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

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

Generator Grounding

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

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

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

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

a. Copper - 10 AWG (5.3 mm 2 ) or larger.

b. Aluminum - 8 AWG (8.4 mm 2 ) or larger.

2. When grounding the generator (Figure 3) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

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

NOTE

When connecting the generator to any buildings electrical system

ALWAYS consult with a licensed electrician.


DCA-300SSK SERIES — GENERAL INFORMATION

DCA-300SSK FAMILIARIZATION

Generator

The MQ Power DCA-300SSK series generators are 240 kW

generators that are designed as a high quality portable

(requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Control Panel

The “ Engine Control Panel ” is provided with the following: z Tachometer z Throttle Handle (Up to S/N 3701673) z Water Temperature Gauge z Oil Pressure Gauge z Charging Ammeter Gauge z Engine Warning Display Module z Engine Speed Switch (S/N 3701674~) z Pre-Heat Button z Pre-Heat Lamp z Emergency Stop Button z Battery Switch z Auto On/Off Engine Controller (S/N 3701674~) z Ignition Switch (Up to S/N 3701673)

Generator Control Panel

The “ Generator Control Panel ” is provided with the following: z Output Voltage Adjustment Knob z Frequency Meter (Hz) z AC Ammeter (Amps) z AC Voltmeter (Volts) z Ammeter Change-Over Switch z Voltmeter Change-Over Switch z Panel Light z Panel Light Switch z Pilot Lamp

Output Terminal Panel

The “ Output Terminal Panel ” is provided with the following: z 3 auxiliary 240/139V output receptacles, 50 amp z 3 auxiliary circuit breakers 240V @50 amps z 2 120V GFCI receptacles, 20 amp z 2 GFCI circuit breakers 120V@ 20amps

Control Box

The “ Control Box ” is provided with the following: z Main Circuit Breaker 800 amps z Over-Current Relay

Open Delta Excitation System

The DCA-300SSK series generators are equipped with the state of the art " Open-Delta" excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the power to the Automatic Voltage Regulator (AVR) is supplied from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " fixed ceiling" and responds according the demands of the required load.

Engine

The DCA-300SSK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D125E-2 diesel engine.

The DCA-300SSK2 and DCA-300SSK3 are powered by a 4 cycle, water cooled, air to air after cooled, turbocharged

KOMATSU Model SAA6D125E-2 diesel engine. These engines are designed to meet every performance requirement for the generator. Reference Table 2 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-300SSK series generators are addressed on the following pages.

Electronic Governor System

The DCA300SSK2 is equipped with an electronic governor system. It is made up of two parts; an electronic controller that monitors frequency variation as the load increases and decreases, and an electronic actuator that controls the engine throttle. Thr frequency is regulated at ±0.25 to help protect sensitive equipment.

Microprocessor Engine Control (MPEC)

The DCA300SSK3 incorporates the use of a microprocessor

engine controller unit (MPEC), which monitors basic engine functions and also allows the generator to operate in an unattended mode.


DCA-300SSK SERIES — MAJOR COMPONENTS

Figure 5. Major Components

T a b l e 4 .

G e n e r a t o r M a j o r C o m p o n e n t s

I T E M N O .

1

2

3

6

7

4

5

8

9

D E S C R I P T I O N

M u f lf e r A s s e m b l y

E n g i n e A s s e m b l y

E n c l o s u r e A s s e m b l y

G e n e r a t o r A s s e m b l y

O u t p u t T e r m i n a l A s s e m b l y

B a tt e r y A s s e m b l y

F u e l T a n k A s s e m b l y

G e n e r a t o r C o n t r o l P a n e l A s s e m b l y

E n g i n e O p e r a it n g P a n e l A s s e m b l y


DCA-300SSK — GENERATOR CONTROL PANEL

S/N 3701673 and Below

S/N 3701674 and Above

Figure 6. Generator Control Panel


DCA-300SSK — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the DCA-300SSK “Control Panel” (Figure 8).

1.

Pilot Lamp – Indicates that the generator is working properly.

2.

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

3.

Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

4.

AC Ammeter – Indicates the amount of current the load is drawing from the generator.

5.

AC Voltmeter – Indicates the single phase output voltage present at the UVWO terminals.

6.

Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off.

7.

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

8.

Panel Light Switch – When activated will turn on control panel light.

9.

Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage.

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

This controller has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault), has been detected. When a fault has been detected the engine controller will evaluate the fault. Any major fault will cause the controller to shutdown the generator.

During cranking cycle , The MPEC will attempt to crank the engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s " Over Crank

Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the " Over Speed Protection" mode.

Also the engine controller will shutdown the generator in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

A.

Off/Manual/Auto Switch – This switch controls the running of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the manual position, the generator will start immediately. If the generator is to be connected to a building's AC power source via a transfer switch

(isolation), place the switch in the auto position. In this position the generator will monitor the AC line output from the building's power source.

B.

Low Oil Pressure – Indicates the engine pressure has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.

C.

High Coolant Temperature – Indicates the engine temperature has exceeded 215°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.

D.

Overcrank Shutdown – Indicates the unit has attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. Typical programmable start settings is 3 cycles with a 10 second duration . This is considered a major fault.

E.

Overspeed Shutdown – Indicates the engine is running at an unsafe speed. This is considered a major fault.

F.

Engine Running – Indicates that engine is running at a safe operating speed.

11. Main Circuit Breaker – This three-pole, 800 amp main breaker is provided to protect the UVWO voltage output terminals from overload.


DCA-300SSK — ENGINE OPERATING PANEL



Figure 7. Engine Operating Panels


DCA-300SSK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-300SSK or DCA-300SSK2 “Engine Operating

Panels” (Figure 7).

1.

Throttle Handle - This handle controls the speed of the engine (low or high).

2.

Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

3.

Engine Warning Display Module – This module display’s the following engine failures:

A.

Overheat Lamp – This lamp goes ON when the cooling water temperature rises abnormally. If the lamp goes ON during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

B.

Low Oil Pressure Lamp – During normal operation of the generator this lamp should remain OFF. When the Auto-OFF/Reset-

Manual switch is set to the “Manual” position to start the engine, the lamp will be lit. After the oil pressure rises after startup the lamp will go OFF. If this lamp is ever lit (ON) during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

C.

Low Fuel Level Lamp – When this lamp is

ON, it is time to stop the engine and add fuel. Remember to let the engine cool before adding fuel.

D.

Low Battery Fluid Lamp – This lamp goes

ON when the battery fluid is low. If this lamp goes ON during normal operation of the generator, stop the engine and fill the battery with distilled water to the specified level.

E.

Clogged Air Filter Lamp – This lamp goes

ON when the air filter is clogged. If this lamp goes ON during normal operation of the generator, stop the engine and replace the air filter.

4.

Oil Pressure Gauge – During normal operation this gauge be should read in the “GREEN” zone. When starting the generator the oil pressure mar read a little bit higher, but after the engine warms up the oil pressure should return to the green zone.

5.

Water Temperature Gauge – During normal operation this gauge be should read in the “GREEN” zone.

6.

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

7.

Fuel Gauge - Indicates amount of diesel fuel available.

8.

Pre-Heat Lamp – Indicates that the glow plugs of the diesel engine are hot and the engine is ready to be started.

9.

Pre-Heat Button – Press and hold this button until the preheat lamp is lit (ON).

10. Emergency Stop Button – Push this button inward to stop the engine in the event of an emergency. DO NOT use this button as a means of stopping the engine.

11. Ignition Switch (Up to S/N3701673) – Four position switch, pre-heat, stop, run and start. Insert ignition key to start and stop engine.

12. Battery Switch – This switch should be set to the ON position during normal operation. When the engine has been stop, place this switch in the OFF position. DO

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

13. Engine Speed Switch (S/N3701674~) – Changes the speed of the engine rpm’s (low or high).


DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “ Output Terminal Panel ” (Figure 8) is provided with the following: z Three 240/139V output receptacles, 50 amp z Three circuit breakers 240V @50 amps z Two 120V GFCI receptacles, 20 amp z Two (2) GFCI circuit breakers 120V@ 20 amps z Eight (8) output terminal lugs

Output Terminal Panel

Shown below (Figure 8) is the Output Terminal Panel , lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

Terminal legs “O” and “Ground” are considered bonded grounds.

Figure 8. Output Terminal Panel



120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over

board position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the UVWO terminals.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the " Test Button" (See Figure 9) in the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

UVWO terminals.

Turn the voltage regulator control knob (Figure 11) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.

Figure 11. Voltage Regulator Control Knob

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 240/139 VAC Receptacles

There are three 240/139 VAC, 50 amp auxiliary twist-lock

(CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can be accessed in any

voltage change-over board position.

Figure 10. 240/139 VAC Twist-Lock

Auxiliary Receptacles



Connecting Loads

Loads can be connected to the generator by the UVWO terminal lugs or the convenience receptacles. (See Figure 12). Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the UVWO output terminals from overload, a 3pole, 800 amp, main circuit breaker is provided. Make sure to switch ALL circuit breakers to the "OFF" position prior to starting the engine.

Over Current Relay

An over current relay (Figure 13) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 13. Over Current Relay

Maximum Power Output (KW)

The entire load connected to the UVWO output terminal lugs, duplex and auxiliary receptacles must not exceed 264 kw in standby or 240 kw in prime output.

Figure 12. Connecting Loads


DCA-300SSK SERIES — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

NOTE

Motors and motor-driven equipment draw much greater current for starting than during operation.

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

T a b l e 5 .

P o w e r F a c t o r B y L o a d

T y p e O f L o a d P o w e r F a c t o r

0 .

4 0 .

7 5 S i n g l e p h a s e i n d u c it o n m o t o r s

E l e c t r i c l a m p s h e a t e r s , i n c a n d e s c e n t

F l u o r e s c e n t l a m p s , m e r c u r y l a m p s

E l e c t r o n i c e q u i p m e n t d e v i c e s , c o m m u n i c a it o n

C o m m o n p o w e r t o o l s

1 .

0

0 .

4 0 .

9

1 .

0

0 .

8

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

z When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

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

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

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

T a b l e 6 .

C a b l e S e l e c t i o n ( 6 0 H z , S i n g l e P h a s e O p e r a t i o n )

M a x i m u m A ll o w a b l e C a b l e L e n g t h L o a d I n W a t t s

C u r r e n t i n

A m p e r e s A t 1 2 0

V o l t s

A

V t o l t

2 4 0 s

2 .

5 3 0 0 6 0 0

# 1 0 W i r e

1 0 0 0 f .t

# 1 2 W i r e

6 0 0 f .t

# 1 4 W i r e

3 7 5 f .t

# 1 6 W i r e

2 5 0 f .t

1 2 5 f .t

1 0 0 f .t

5

7 .

5

1 0

1 5

2 0

1

1

2

6

9

2

8

4

0

0

0

0

0

0

0

0

0

0

1

1

2

3

4

2

8

4

6

8

0

0

0

0

0

0

0

0

0

0

5

3

2

1

1

0

5

5

0

0

0

5 0

2 5 f f f f f

.t

.t

.t

.t

.t

3

2

1

1

7

0

0

5

0

5

0

0

0

0

C A U T I O N : E q u i p m e n t d a m a g e c a n r e s u tl f r o m l o w v o tl a g e .

f f f f .t

f .t

.t

.t

.t

2 0 0 f .t

1 2 5 f .t

1 0 0 f .t

6 5 f .t

5 0 f .t

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

NOTE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.


DCA-300SSK SERIES — GENERATOR OUTPUTS

Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the voltage change-over board (Figure 14).

To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the voltage regu-

lator (VR) control knob located on the control panel.

Voltage Change-Over Board

The voltage change-over board (Figure 14) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

T a b l e 8 .

G e n e r a t o r A m p e r e R a t i n g s

8 0

1 0 0

1 2 0

1 4 0 k W

2 0

4 0

6 0

1 6 0

1 8 0

2 0 0

2 2 0

2 4 0 ( M a x )

1

1

1

1

1

1

1

3

1

2

4

5

7

8

0

1

2

4

5

7

8

3

7

1

6

9

4

0

5

9

3

8

2

8

2

6

9

3

V

4

7

1

5

9

3

7

2 4 0 V

8 3

1 6 7

2 5 0

3 3 3

4 1 7

5 0 0

5 8 3

6 6 7

7 5 0

8 3 3

9 1 7

1 0 0 0

2 7 7 V

7 2

1 4 4

2 1 7

2 8 9

3 6 1

4 3 3

5 0 5

5 7 8

6 5 0

7 2 2

7 9 4

8 6 6

4 8 0 V

4 2

8 3

1 2 5

1 6 7

2 0 8

2 5 0

2 9 2

3 3 3

3 7 5

4 1 7

4 5 8

5 0 0

Figure 14. Voltage Change-Over Board

240V Configuration

CAUTION - CHANGING VOLTAGES

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!

T a b l e 7 .

G e n e r a t o r A v a li a b l e V o l t a g e s

T h r e e P h a s e 2 0 8 V 2 2 0 V 2 4 0 V 4 1 6 V 4 4 0 V 4 8 0 V

S i n g l e P h a s e 1 2 0 V 1 2 7 V 1 3 9 V 2 4 0 V 2 5 4 V 2 7 7 V

T a b l e 9 .

G e n e r a t o r A m p e r e R a t i n g s

1 8 0

2 0 0

2 2 0

2 4 0

1 0 0

1 2 0

1 4 0

1 6 0

K W

2 0

4 0

6 0

8 0

5 4 1

6 0 1

6 6 2

7 2 2

3 0 1

3 6 1

4 2 1

4 8 1

2 4 0 V

6 0

1 2 0

1 8 0

2 4 1

1 5 0

1 8 0

2 1 0

2 4 1

2 7 1

3 0 1

3 3 1

3 6 1

4 8 0 V

3 0

6 0

9 0

1 2 0


DCA-300SSK SERIES — GENERATOR OUTPUTS/GAUGE READING

Maximum Amps

Table 10 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.

T a b l e 1 0 .

G e n e r a t o r M a x i m u m A m p s

M o d e l :

D C A 3 0 0 S S K

S e r i e s

M a x i m u m A m p s R a t e d V o l t a g e

S i n g l e

1 2 0

P h a s e

V o tl

S i n g l e

2 4 0

P h a s e

V o tl

T h r e e

2 4 0

P h a s e

V o tl

T h r e e

4 8 0

P h a s e

V o tl

2

1

0

0

0

0

0

0

7

3 a a

2

6 m m

0

0 p p a a s s m m

(

(

4

4 p p s s w w i i r r e e

)

)

Figure 16. AC Voltmeter

Change-Over Switch

Figure 17. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

20

40

How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output.

They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø,

240V operation (See Figure 15), place the AC Voltmeter

Change-Over Switch (Figure 16) to the W-U position and the AC Ammeter Change-Over Switch (Figure 18) to the U or W position to read the output on the selected leg.

Figure 18. AC Ammeter

Change-Over Switch

0

A

60

75

Figure 19. AC Ammeter

(Amp reading on U lug)

NOTE

The ammeter and voltmeter gauges are only active when the

UVWO terminals are in use.




DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the

Voltage Change-Over Board and the adjustment of the

Voltage Regulator Control Knob.

Remember the voltage change-over board determines the

range of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator

(VR) allows the user to increase or decrease the selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 20.

Figure 22. Voltage Regulator Knob


1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20 .

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 23. UVWO Terminal Lugs

1Ø-240V Connections





1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20.




3. Turn the voltage regulator knob (Figure 22) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required




DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS


1. Jumper the voltage change-over board for 480V operation as shown in Figure 25. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.












NOTE



ALWAYS make sure that the connections to the UVWO terminals are secure and tight.

The possibility of arcing exists, that could cause a fire.




DCA-300SSK SERIES — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 800 amp,

main circuit breaker is provided to protect the UVWO output terminals from overload. In addition two single-pole, 20 amp

GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the "OFF" position prior to starting the engine.

Fuel Check

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a hot engine can cause a fire or explosion.

If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level.

Also verify that the oil level is maintained between the two notches (Figure 29) on the dipstick. See Table 11 for proper selection of engine oil.

Figure 29. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Komatsu Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements: z API Service Classification CH-4 z API Service Classification CG-4 z API Service Classification CF-4 z ACEA Specification E3 z ACEA Specification E2

REFILLING THE FUEL SYSTEM

The DCA300SSK series generators may (if equipped with a trailer or skid) have a double fuel tank system (Figure 30), which consists of an internal generator fuel tank, and a

trailer mounted fuel tank. It is also possible the generator can be equipped with a skid mounted fuel tank (Figure 31).

The skid type fuel system does not use the internal generator fuel tank.

Use the instructions in this section that applies to your type of fuel tank system.

ALWAYS fill the fuel tank with clean and fresh #2 diesel

fuel. DO NOT fill the fuel tanks beyond their capacities.

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

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

T a b l e 1 1 .

R e c o m m e n d e d M o t o r O li

T y p e O li T e m p e r a t u r e R a n g e

7 7 o F

( 2 5 o C a n d a n d g r g r e a t e r e a t e r )

3 2 o F

( 0 o C t t o o

7 7 o F

2 5 o C )

2 2 o F t o 3 2

( 3 0 o C 0 o C ) o F

S A E 1 5 W 4 0 o r S A E 4 0

S A E 1 0 W 3 0 o r S A E 3 0

S A E 1 0 W 3 0 o r S A E 1 0

Figure 30. Double Fuel Tank System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and understand this section should refill the fuel tank system.



CAUTION - REFUELING TRAILER FUEL TANK

ALWAYS! fill trailer tank first with #2 diesel fuel, before filling secondary internal tank.

Figure 31. Skid Type Fuel Tank System

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

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. See Figure 32.


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 33. Fuel Tank Filling Order

NOTE

ONLY! use #2 diesel fuel when refueling.

Figure 32. Only Fill on Level Ground

2.

Trailer Fuel Tank First – The trailer fuel tank is the primary fuel tank and holds a larger capacity of fuel.

The fuel in the trailer will be filtered and sent to the engine. ALWAYS fill trailer fuel tank (Figure 33) first.

NOTE

Fuel from the secondary inner tank will eventually drain into the primary trailer tank.



3.

NEVER overfill trailer fuel tank – It is important to read the trailer fuel gauge when filling trailer fuel tank.

DO NOT wait for fuel to rise in filler neck. See Figure 34.

5.

Figure 36 below reflects a full fuel system.

Figure 34. Full Trailer Tank

Figure 36. Full Fuel System


DO NOT OVER-FILL fuel system. Leave room for fuel expansion. Fuel expands when heated.

6.

Fuel from the engine return line will drain into the secondary internal fuel tank. This fuel will eventually drain into the primary trailer tank in order to return to the engine.

4.

Once the trailer tank is full, the secondary inner tank can be filled (See Figure 35). Notice how the trailer filler tube level rises when the internal tank is filled.

WARNING - REFUELING SECONDARY FUEL TANK

It is recommended to only fill the internal secondary fuel tank to

3/4 full in order to allow for fuel return, fuel expansion, and to avoid spillage. See Figure 37 for fuel expansion.

Figure 37. Fuel Expansion

Figure 35. Filling Secondary Internal Fuel Tank



Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced.

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be less than 50%.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. See the engine manual for further details.


If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See

Table 11 for engine and radiator, coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

Cleaning the Radiator

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

negative battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Komatsu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the

Komatsu Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 38) when depressed with the thumb as shown below.

T a b l e 1 1 .


E n g i n e T y p e

K o m a t s u S A 6 D 1 2 5 E 2

K o m a t s u S A A 6 D 1 2 5 E 2


8 .

5 G a .l

( 3 2 .

6 L ti e r s )

9 .

8 G a .l

( 3 7 .

0 L ti e r s )

Figure 38. Fan Belt Tension

Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 12) has been added.

CAUTION - ROTATING PARTS

T a b l e 1 2 .

A n t i F r e e z e O p e r a t i n g T e m p e r a t u r e s

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

F r e e z i n g P o i n t

A n t

V o l

-i F r

% e e z e

° C ° F

B o i il n g P o i n t

° C ° F

4 0 2 4 1 2 1 0 6 2 2 2

5 0 3 7 3 4 1 0 8 2 2 6



Battery

This unit is of negative ground DO NOT connect in reverse.

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

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened.

Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

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

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 39) are properly connected to the battery terminals as shown below. The

RED cable is connected to the positive terminal of the battery, and the BLACK cable is connected to the negative terminal of the battery.

CAUTION - BATTERY SERVICING SAFETY

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

NOTE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

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

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( fuel or oil) lines are defective replace them

immediately.

Figure 39. Battery Connections

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the ignition switch is in either the Pre-

Heat, RUN, or START position. ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

If applicable perform the following:

■ Apply commercial power to the internal battery charger receptacle (to ensure good starting) via commercial power.

An external power cord will be required. This capability is an

option.

■ Apply commercial power to the jacket water heater receptacle (not necessary for warm climates) via commercial power. An external power cord will be required. This capability is an option.


DCA-300SSK SERIES — GEN. START-UP PROCEDURE (MANUAL)

BEFORE STARTING (S/N 3701673 and below)

NOTE

Steps 1 thru 20 are referenced for Engine Operating Panel S/N

3701673 and below. See Figure

40 below. This unit has an igni-

tion switch and a throttle

handle.

1. Place the main, G.F.C.I. and aux. circuit breakers (Figure 42) in the “OFF” position prior to starting the engine.

Figure 42. Main, Aux. and GFCI

Circuit Breakers (OFF)

Figure 40. Engine Operating Panel


CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

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

3. Connect the load to the UVWO terminals or auxiliary

receptacles as shown in Figure 12. These load connection points can be found on the output terminal panel. To gain access to the UVWO terminals or other power receptacles, unlock the access cover and lift the door.

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

5. Close all engine enclosure doors (Figure 42).

WARNING - STARTING THE GENERATOR

NEVER! manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

Figure 42. Engine Enclosure Doors


DCA-300SSK SERIES — GENERATOR START-UP PROCEDURE (MANUAL)

6. Set the battery ON/OFF switch (Figure 43) to the “ON” position.

12. The generator's frequency meter (Figure 48) should be displaying the 60 cycle output frequency in HERTZ.

Figure 43. Battery ON/OFF Switch

7. When starting the generator in COLD weather conditions, turn the ignition key to the “PREHEAT ” position (Figure 44).

Figure 48. Frequency Meter (Hz)

13. The generator's AC-voltmeter (Figure 49) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 50) to increase or decrease the desired voltage.

Figure 44. Ignition Switch (Pre-Heat)

8. Press and hold the engine preheat button (Figure 45) until the preheat lamp is lit (ON).

Pre-Heat

Button

Pre-Heat

Lamp

Figure 49. Voltmeter

Figure 45. Pre-Heat Button/ Lamp

9. Place the engine throttle control in the “LOW” position

(Figure 46).

Figure 50. Voltage Adjust Control Knob

Figure 46. Engine Throttle Control

10. Turn the ignition key to the “START” position (Figure 47) and listen for the engine to begin cranking. After the engine starts release the ignition key.

14. The ammeter (Figure 51) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 51. Ammeter (No Load)

Figure 47 Engine Ignition Switch

11. Once the engine has started, let it run for 3-5 minutes, then turn the throttle handle control (Figure 46) to the

“HIGH” position.



15. The engine oil pressure gauge (Figure 52) will indicate the oil pressure (kg/ cm 2 ) of the engine. Under normal operating conditions the oil pressure is approximately

18. Place the main, GFCI, and aux. circuit breakers in the

“ON” position (Figure 55).

0 kg/cm2

4

8

ENGINE OIL PRESSURE

Figure 52. Oil Pressure Gauge

16. The coolant temperature gauge (Figure 53) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between

165 and 215 degrees Fahrenheit ( Green Zone).

WATER TEMP


Circuit Breakers (ON)

19. Observe the generator's ammeter (Figure 56) 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 53. Coolant Temperature Gauge

17. The tachometer gauge (Figure 54) will indicate the speed of the engine when the generator is operating.

Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 56. Ammeter (Load)

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

Figure 54. Engine Tachometer Gauge



BEFORE STARTING (S/N 3701674 and above)

NOTE

4. Place the engine speed switch in the “ LOW ” position

(Figure 60) .

Steps 1 thru 8 are referenced for Engine Operating Panel

S/N 3701674 and above. See

Figure 57 below. This unit does not have an ignition switch or a throttle handle. It does have an

“ engine speed switch” that is used in conjunction with the

MPEC unit.

Figure 60. Engine Speed Switch (Low)

5. Place the Auto-Off/Reset-Manual switch in the “ Manual” position to start the engine (Figure 61). Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 61. Auto-Off/Reset-Manual Switch

6. Once the engine is warm and the engine is running properly, place the engine speed switch in the “ HIGH ” position

(Figure 62).

Figure 57. Engine Operating Panel


1. Before attempting to start generator, reference steps

1 thru 5 in the “ Before Starting Section” for Engine

Operating Panel S/N 3701673 and below.

Figure 62. Engine Speed Switch (High)


7.

Verify that the "Engine Running" status LED on the MPEC unit (Figure 63) is "ON" (lit) after the engine has been started.


3. Press and hold the engine preheat button (Figure 59) until the preheat lamp is lit (ON).

Pre-Heat

Button

Figure 63. Engine Running LED (ON)

Pre-Heat

Lamp 8. Continue operating the generator as outlined in steps 11 thru 20 in the “ Before Starting Section” for Engine


Figure 59. Pre-Heat Button/ Lamp


DCA-300SSK SERIES — GEN. START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

When starting generator in AUTO mode use the " Manual

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

1. Before attempting to start generator, reference steps

1 thru 5 in the “ Before Starting Section” for Engine



CAUTION - BACKUP GENERATOR USE

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.


3. Set the engine speed switch (Figure 65) to the “High” position.

NOTE

When the generator is set in the

AUTO mode, the generator will

automically start in the event of comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.


4. Place the Off/Manual/Auto switch (Figure 66) on the

MPEC unit to the AUTO position.

WARNING - AUTO MODE MAINTENANCE

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.

Figure 66. Off/Manual Auto Switch (AUTO)

5. Continue operating the generator as outlined in steps 11 thru 19 in the “ Before Starting Section” for Engine


CAUTION - ENGINE SPEED SWITCH

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.

NOTE

When the MPEC Control Switch is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.


DCA-300SSK SERIES — GEN. SHUT-DOWN PROCEDURE (MANUAL)

Engine Shutdown Ignition Key (Up to S/N 3701673)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers

(Figure 67) to the "OFF position".

Engine Shutdown Controller (S/N 3701674~)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 67 to the "OFF position".

2. Place the engine speed switch in the “ LOW ” position

(Figure 71).



Circuit Breakers (OFF)

2. Place the throttle control (Figure 68) in the “LOW” position.

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

4. Place the Auto-Manual/Off/Reset switch (Figure 72) to the OFF/Reset position.

Figure 68. Engine Throttle Control

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

4. Place the ignition key (Figure 69) in the “STOP” position.

Figure 72. Auto-Manual Off/Reset Switch

5. Verify that the all status LED on the MPEC display are

"OFF" (not lit).

6. Remove all loads from the generator.

WARNING - SHUTTING DOWN THE GENERATOR

Figure 69. Ignition Key Switch (STOP position)

5. Remove all loads from the generator.

NEVER stop the engine suddenly except in an emergency.

DO NOT use the emergency stop switch a as method of shutting down the generator. This switch is ONLY to be used in the event of an emergency.

Emergency Shutdown Procedure

1. PUSH inward the RED emergency stop button located on the engine operating panel (Figure 70) to turn off the generator in the event of an emergency. This button is located on either Engine Operating Panel.

NOTE

To disengage the emergency stop function, pull the emergency stop button outward to its original position. This will allow the generator to operate normally. Remember the generator will not start if the emergency stop button is engaged.

Figure 70. Emergency Stop Button


NOTE PAGE


DCA-300SSK SERIES — MAINTENANCE

Use Table 13 shown below as a general checklist to be performed on a daily basis.

T A B L E 1 3 .

I N S P E C T I O N / M A I N T E N A N C E

E N G I N E

G E N E R A T O R

C h e c k E n g i n e F l u i d L e v e l s

C h e c k F u e l F i tl e r

C h e c k A ri C l e a n e r D u s t I n d i c a t o r

C h e c k f o r L e a k s / V i s u a l W a l k A r o u n d

C h e c k f o r L o o s e n i n g o f P a r t s

R e p l a c e E n g i n e O li a n d F i tl e r * 1

S e r v i c e B a tt e r y

C l e a n U n i ,t I n s i d e a n d O u t s i d e

C h a n g e F u e l F i tl e r * 2

C l e a n

P r o t e c it

R o a d i n a t o r

L e v e l a n d C h e c k C o o l a n t

R e p l a c e A ri F i tl e r E l e m e n t

T e s t T h e r m o s t a t s

C h e c k a ll H o s e s a n d C l a m p s / F l u s h R a d i a t o r

C l e a n I n s i d e o f F u e l T a n k

M e a s u r e o h m s

I n s u l a it o n R e s i s t a n c e O v e r 3 M

1 0 H r s

D A I L Y

X

X

X

X

X

2 5 0 H r s 5 0 0 H r s 1 0 0 0 H r s

X

X

X

X

X

X

X

X

X

X

* 1 R e p l a c e e n g i n e o li a n f if tl e r a t 1 0 0 h o u r s , f ri s t it m e o n l y .

* 2 R e p l a c e f u e l if tl e r a t 2 5 0 H o u r s , f ri s t it m e o n l y .



General Inspection

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

Air Cleaner

Every 50 hours: If dust indicator is RED, clean the air cleaner element.

Outer Element:

1. Loosen wing bolt, remove dust cup, then remove wing nut and take out element.

2. Clean the inside of the body and cover using a damp cloth.

3. Blow dry with compressed air (0.69Mpa {7kgf.cm

2 ,

99.4 PSI} maximum) against the side of the element along the pleats. Then blow dry against outside along the pleats, then against inside again.

4. Remove one seal each time the element is cleaned.

5. Replace the outer element after cleaning it 6 times or after one year. Replace the outer element if indicator is red even after cleaning it.

6. Check the inner cylinder element clamping nut for looseness, and retighten if necessary.

7. If seal washer is damaged or the threads of wing nut are damaged, replace.

8. Remove evacuator valve and clean it with compressed air. Reinstall.

Inner element (if equipped)

1. Remove the cover and outer element, then remove the inner element.

2. Cover the air connector opening (outer side) with clean cloth or cloth tape.

3. Clean the inside of the body. Remove air connector opening protection.

4. Install a new inner cylinder element to the cylinder and tighten the nut.

5. Install element.

6. After replacing the element, press the button of the dust indicator to return the red piston to its original position.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

Removing Water from the Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally remove the drain cock and drain the contents. During cold weather, the greater the empty volume inside the tank, the easier it is for water to condense. This can be reduced by always keeping the tank as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure.

To restart after running out of fuel, turn the key switch to the

“START” position for 15-30 seconds. Try again, if needed.

This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions, a clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in diesel. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 29.

Check Electric Heater (If equipped)

Before starting in cold weather (once a year), please contact your Komatsu distributor for inspection. Remove electric heater from the engine intake manifold and check for disconnections or dirt. When checking or installing the electric heater, replace the gasket with a new part.



Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.



14. Drain the water inside reserve tank, clean the inside of the reserve tank, then fill with coolant/water mixture to between the full and low lines.

Flushing Out Radiator and Changing Coolant

1. Stop the engine and allow to cool. Tighten valve of the corrosion resistor (if equipped).

2. Turn water filer cap slowly and remove it.

15. Stop the engine, wait for 3 minutes, add tap water until the water level reaches near the water filer port, then tighten the radiator cap.

Changing Oil

1. Make sure the oil is cool before changing.

2. Set a container directly under the drain plug of the oil pan. Loosen the drain plug slowly.

3. Check the drained oil for excessive metal particles or foreign material. Contact the distributor if there is metal particles or foreign material.

4. Using a filter wrench, turn filter cartridge to the left to remove it. If the filter cartridge is filled with a large amount of oil, wait 10 minutes or so before removing.

Make sure there is no old gasket stuck on the filter holder.

3. Prepare a container to catch the coolant, then open drain plug of the radiator or heat exchanger and drain plug of the engine, and drain the coolant.

4. After draining the coolant, close drain plugs and fill with tap water.

5. When the water level is near the mouth of the water filler, open drain plugs and start the engine, and run at low idling. Keep the engine running at low idling and flush the radiator for about 10 minutes.

6. Adjust the flow of the water flowing in and draining out to ensure that the radiator is always full during the flushing operation. While flushing water through the system, watch carefully the water inlet hose does not come out of the radiator filler port.

7. After flushing, stop the engine, open drain plug and drain the water, then close drain plugs.

8. After draining the water, flush the system with a flushing agent. See instructions on flushing agent label.

9. After flushing, open drain plugs and drain out all the water, then close drain plugs and add tap water so the water level is near the mouth of the water filler.

10. When the water level is near the mouth of the water filler, open drain plugs and start the engine, run at low idling and continue to flush the system until clean water comes out. Adjust the flow of the water flowing in and draining out to ensure the radiator is always full during the flushing operation.

11. When clean water comes out, stop the engine, drain all the water, then close drain plugs.

12. Remove the corrosion resistor (if equipped) and open valve.

13. Supply water until it flows over the water filler.

5. Tighten drain plug. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the packing and thread of the new filter cartridge with engine oil, then install it to the filter holder. Tighten until the gasket surface contacts the seal surface of the filter holder, then tighten it a further 3/4 to 1 turn.

6. Add engine oil through oil filler until the oil level is between the H and L marks on the dipstick.

7. Run the engine at idling for a short time, then stop the engine. Recheck the oil level and fill as necessary.

Replacing Fuel Filter

1. Set the container under the filter cartridge to catch fuel.

2. Using a filter wrench, turn the filter cartridge to the left to remove it.

3. Clean the filter holder, fill the new filter cartridge with fuel, coat the packing surface of the filter cartridge with engine oil, then install the cartridge to the filter holder.

4. When installing, tighten until the packing surface contacts the seal surface of the filter holder then tighten a further 2/3 of a turn. If the filter cartridge is tighten too much, the packing will be damaged and will cause fuel leakage. Fuel leakage will occur if the filter cartridge is not tightened enough. Always tighten to the correct angle.



5. After replacing filter cartridge, loosen air bleed plug.

6. Loosen the knob of feed pump, and pump it up and down until no bubbles come out with the fuel from air bleed plug.

7. After bleeding the air, tighten air bleed plug, then push in the knob of feed pump and lock it in position.

8. Replace Corrosion resistor cartridge (if equipped)

9. Screw in valves at the top of the corrosion resistor.

10. Using a filter wrench, turn the cartridge to the left to remove it.

11. Coat the seal surface of the new cartridge with engine oil and install it to the filter holder.

12. Tighten until he packing surface contacts the seal surface of the filter holder, then tighten a further 2/3 of a turn.

13. Open valves.

Cleaning Breather Element

1. Loosen the clamp, then remove the hose and take out breather. Wipe off the dirt around the breather. Check the O-ring, and replace if necessary.

2. Wash the breather in diesel fuel or flushing oil, blow dry with compressed air, then reinstall it.

3. Inspect the hose and if there is any deteriorated oil stuck inside the hose. Replace hose if necessary.

Greasing

1. Using a grease pump, grease the fan hub (1 place) and tension pulley (2 places).

Generator Storage:

For storage of the generator for over 30 days, the following is required: z Fill the fuel tank completely. Treat with fuel stabilizer if necessary.

z Completely drain oil from the crankcase and refill if necessary with fresh oil.

z Clean the entire generator, internal and external.

z Disconnect the negative terminals of the battery and cover it, or remove it from the generator and store it separately.

z If the ambient temperature is expected to drop below

0 o C, add antifreeze to the radiator.

z Cover the generator set and store in a clean, dry place

Removal From Long Term Storage: z Apply oil to the engine valve and rocker arms, and examine the operating condition of the valves.

z Remove the oil filler pipe from the turbocharger oil inlet port, add 0.5-1L (0.13-0.26 gal) of oil to the turbocharger, reinstall the oil filler pipe.

z Change the oil in engine oil pan.

z Replace all the filters.

z Flush the inside of the cooling system.

z Drain the water from the fuel tank and bleed the air from the fuel system.

z If the engine has not been started for more than one year, contact your Komatsu distributor to have engine overhauled.



Jacket Water Heater and Internal Battery Charger 120

VAC Input Receptacles (OPTIONAL)

This generator is equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 73). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger.

Figure 73. Battery Charger/Jacket Water

Heater Power Connections


DCA-300SSK SERIES —TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-400SSVU

Whisperwatt ™ Generator.

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

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

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

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - Measurement is from fender to fender

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

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

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

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

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

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

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 64 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

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

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

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



Brakes

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

every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Figure 74 displays the major hydraulic surge brake components that will require inspection and maintenance.

Use Table 14 as a basic trouble shooting guide when brake problems occur. Please inspect these components as required using steps 1 through 6 as listed below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

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

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

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

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

Hydraulic Surge Brakes

Hydraulic surge brakes should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 74. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “ actuator ” to make sure that it is functioning correctly. Never use an undersize actuator.

T a b l e 1 4 .

H y d r a u il c B r a k e T r o u b l e s h o o t i n g

S y m p t o m P o s s i b l e C a u s e S o l u t i o n

N o B r a k e s B r a k e il n e b r o k e n o r k i n k e d ?

B r a k e il n i n g g l a z e d ?

R e p a ri o r r e p l a c e .

R e b u r n i s h o r r e p l a c e .

W e a k B r a k e s o r B r a k e s P u ll t o

O n e S i d e

L o c k i n g B r a k e s

N o i s y B r a k e s

D r a g g i n g B r a k e s

T r a li e r o v e r l o a d e d ?

B r a k e d r u m s s c o r e d o r g r o o v e d ?

T ri e p r e s s u r e c o r r e c t ?

T ri e s u n m a t c h e d o n t h e s a m e a x l e ?

B r a k e c o m p o n e n t s l o o s e , b e n t o r b r o k e n ?

B r a k e d r u m s o u t o f r o u n d ?

S y s t e m l u b r i c a t e d ?

B r a k e c o m p o n e n t s c o r r e c t ?

B r a k e il n i n g t h i c k a d j u s t e d n e s s c o r r i n c o r r e c t e c lt y ?

o r n o t

E n o u g h b r a k e lf u i d o r c o r r e c t lf u i d ?

C o r r e c t w e i g h .t

M a c h i n e o r r e p l a c e .

I n lf a t e a ll t ri e s e q u a ll y .

M a t c h t ri e s .

R e p l a c e c o m p o n e n t s .

R e p l a c e .

L u b r i c a t e .

R e p l a c e a n d c o r r e c .t

I n s t a ll n e w s h il n i n g s .

o e s a n d

R e p l a c e if ll w ti h r u b b e r d o t 4 p a r t s lf u i d .



Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

The leaf suspension springs and associated components

(Figure 75) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components as detailed in Table 16.

CAUTION - EYESIGHT HAZARD

ALWAYS wear safety glasses when removing or installing force fitted parts.

Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

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.

Figure 75. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 15 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

T a b l e 1 6 .

S u s p e n s i o n T o r q u e R e q u i r e m e n t s

I t e m

3 / 8 " U B O L T

7 / 1 6 " U B O L T

1 / 2 " U B O L T

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

T o

M

M I r

I q

N

N -

u

3

4 e

0

5

( F

M

M t .

A

A

L

X

X -

b

3

6 s

5

0

.

)

M I N 4 5 M A X 6 0

SNUG FIT ONLY

.

PARTS MUST ROTATE FREELY

.

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

-

BOLT ASSEMBLY

.

M I N 3 0 M A X 5 0



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 77. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 17.

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

Check all wheel lug nuts periodically.

W h e e l S i z e

1 2 "

T a b l e 1 7 .

T i r e T o r q u e R e q u i r e m e n t s

F i

F r s

T t

L

P a s s

B

2 0 2 5

S

S e c o n d P a s s

F T L B S

3 5 4 0

T h i r d P a

F T L B S s s

5 0 6 5

1 3 "

1 4 "

2 0 2 5

2 0 2 5

3 5 4 0

5 0 6 0

5 0 6 5

9 0 1 2 0

1 5 "

1 6 "

2 0 2 5

2 0 2 5

5 0 6 0

5 0 6 0

9 0 1 2 0

9 0 1 2 0

Figure 76. Wheel Lug Nuts Tightening Sequence

NOTE

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

Use a torque wrench to tighten lug nuts.


DCA-300SSK — TRAILER-WIRING DIAGRAM

Figure 77. Trailer/Towing Vehicle Wiring Diagram


DCA-300SSK — GENERATOR WIRING DIAGRAM

Figure 78. Generator Wiring Diagram


DCA-300SSK— ENGINE WIRING DIAGRAM (S/N 3696506 AND BELOW)

Figure 79. Engine Wiring Diagram (S/N 3696506 and Below)


DCA-300SSK — ENGINE WIRING DIAGRAM (S/N3696507 TO 3701673)

Figure 80. Engine Wiring Diagram (S/N 3696507-3701673)


DCA-300SSK — ENGINE WIRING DIAGRAM (S/N 3701674 AND ABOVE)

Figure 81. Engine Wiring Diagram (S/N 3701674 and Above)


DCA-300SSK — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (Engine Troubleshooting) as a basic guideline for troubleshooting the engine. If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

E n g i n e d o e s n o t s t a r t .

S t a r t e r d o e s n o t r u n .

T A B L E 1 8 .

E N G I N E T R O U B L E S H O O T I N G

N

A o

F u ri

W a t e l f u i n e r

P e p i l

O S

?

t h e i n p e f

S I c

B L u e l t h e f u l o g s

E y s e l

P g e d ?

R O t e m ?

s y s t

B L E M e m ?

S O L U T I O N

R e p l e n i s h f u e .l

B l e e d s y s t e m .

R e m o v e w a t e r f r o m f u e l t a n k .

C l e a n f u e l p i p e .

C l e a n o r c h a n g e f u e l if tl e .r

I

I

F u e l if tl e r c l o g g e d ?

t f

E x c u e l e s s i o r v e e n l y g i n h i g h e o li e m p e r a t u r e ?

v i s c o s a t l o w ti y o f

F u e l w ti h l o w c e t a n e n u m b e r ?

F u e l p i p e r l e a k e t d u e a i n i n g t o n u t l o o s e

?

i n j e c it o n

I n c o r r e c t i n j e c it o n it m i n g ?

F u n j n j e e c e c l it it c o o a n n m n p s o u h a z z m p tf l e w c m o r a fl n ?

l o g u g e d ?

n c it o n i n g ?

U

U

T s s i g e e t t h e h e h t e n s p e c i if e d s p e c i n u .t

if e d f u e l f u e

A d j u s .t

R e p l a c e .

C l e a n i n j e c it o n n o z z l e .


.l

o r e n g i n e o i .l

I

S e i z u r e p i s t o n , c o f y c r a n il n d e r k il s h a f n e r

,t o r c a m s h a f b e a r i n g ?

,t


C o m p r e s s i o n c y il n d e r ?

l e a k f r o m R e p n o z z l a l e c e h o h e a d l d e .r

g a s k e ,t it g h t e n c y il n d e r h e a d b o l ,t g l o w p l u g a n d m

P i s

E p r x c o p t o n e s s i e r v r i n g v e a v l v a l e a n d v e it m il n c l i n e r g ?

w o r e a r a n ?

n c e ?

C o r r e c t o r r e p l a c e it m i n g g e a .r

R e p l a c e .

A d j u s .t

B a tt e r y d i s c h a r g e d ?

S t a r t e r m a fl u n c it o n i n g ?

K e y s w ti c h m a fl u n c it o n i n g ?

W i ir n g d i s c o n n e c t e d ?

C h a r g e b a tt e r y .



C o n n e c t w i ir n g .


DCA-300SSK — TROUBLESHOOTING (ENGINE)

T A B L E 1 8 .

E N G I N E T R O U B L E S H O O T I N G ( C O N T I N U E D )

S O L U T I O N S Y M P T O M P O S S I B L E P R O B L E M

F u e l if tl e r c l o g g e d o r d ri t y ?

A ri c l e a n e r c l o g g e d ?

F u e l p i p e r l e a k e t d u e a i n i n g t o l o o s e n u t ?

i n j e c it o n

I n j e c it o n p u m p m a fl u n c it o n i n g ?

E n s m g i o n e o t h .

r e v o l u it o n i s n o t

I n c o r r e c t p r e s s u r e ?

n o z z l e o p e n i n g

I n j e c it o n c l o g g e d ?

n o z z l e s t u c k o r

F u e l o v e r lf o w p i p e c l o g g e d ?

G o v e r n o r m a fl u n c it o n i n g ?

E x c e s s i v e e n g i n e o li ?

E i s ti h o e r b s e w h r ti e v e d .

o r b l u e e x h a u s t g a s

P s t i s u t c o n k ?

r i n g a n d il n e r w o r n o r


D e if c i e n t c o m p r e s s i o n ?

O v e r l o a d ?

E ti h e x h e r a u s b l a c k t g a s o r i s d a r k g r a y o b s e r v e d .

D e if c i e n t o u t p u .t

L o w g r a d e f u e l u s e d ?

F u e l if tl e r c l o g g e d ?

A ri c l e a n e r c l o g g e d ?

D e if c i e n t n o z z l e i n j e c it o n ?


E n b e g i s n e ' s e i z i n m g ?

o v i n g p a r t s s e e m t o

U n e v e n f u e l i n j e c it o n ?

D e if c i e n t n o z z l e i n j e c it o n ?

C o m p r e s s i o n l e a k ?

C l e a n o r c h a n g e .


T i g h t e n n u .t


A d j u s .t


C l e a n .

R e p a ri .

R e d u c e t o t h e s p e c i if e d l e v e .l


A d j u s .t

A d j u s t t o p c l e a r a n c e .

L e s s e n t h e l o a d .

U s e t h e s p e c i if e d f u e .l



R e p a ri o r r e p l a c e t h e n o z z l e .

A d j u s .t


R e p a ri o r r e p l a c e t h e i n j e c it o n p u m p .

R e p a ri o r r e p l a c e t h e n o z z l e .

R e p l a c e n o z z l e h e a d h o l d e r .

g a s k e ,t it g h t e n c y il n d e r h e a d b o l ,t g l o w p l u g a n d


DCA-300SSK — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 (Generator Troubleshooting) as a basic guideline for troubleshooting the generator. If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

N o V o tl a g e O u t p u t

L o w V o tl a g e O u t p u t

H i g h V o tl a g e O u t p u t

C ri c u ti B r e a k e r T ir p p e d

T A B L E 1 9 .

G E N E R A T O R T R O U B L E S H O O T I N G

P O S S I B L E P R O B L E M

A C V o tl m e t e r d e f e c it v e ?

I s w i ir n g c o n n e c it o n l o o s e ?

I s A V R d e f e c it v e ?

S O L U T I O N

C h e c k o u t p u t v o tl a g e u s i n g a v o tl m e t e .r

C h e c k w i ir n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

D e f e c it v e R o t a it n g R e c it if e r ?

I s e n g i n e s p e e d c o r r e c t ?

I s w i ir n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

I s w i ir n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

S h o r t C ri c u ti i n l o a d ?

O v e r c u r r e n t ?

D e f e c it v e c ri c u ti b r e a k e r ?

O v e r c u r r e n t R e l a y a c t u a t e d ?

C h e c k a n d r e p l a c e .

T u r n e n g i n e t h r o t lt e l e v e r t o " H i g h " .





C h e c k l o a d a n d r e p a i .r

C o n f ri m l o a d r e q u ri e m e n t s a n d r e d u c e .

C h e c k a n d r e p l a c e .

C o n f ri m l o a d r e q u ri e m e n t a n d r e p l a c e .


DCA-300SSK — TROUBLESHOOTING (ENGNE CONTROLLER)

T A B L E 2 0 .

E N G I N E C O N T R O L L E R T R O U B L E S H O O T I N G ( M P E C )

S y m p t o n P o s s i b l e C a u s e i

L s o w o n .

o li p r e s s u r e il g h t

L o w o li l e v e l ?

O li p r e s s u r e s e n d i n g u n ti f a li u r e ?

T i m e d e l a y m a fl u n it o n i n C o n t r o ll e r ?

W ri e s h o r t e d ?

L o w c o o l a n t l e v e l ?

S e n d i n g u n ti f a li u r e ?

L o w i s o n .

c o o l a n t l e v e l il g h t

L o w b a tt e r y v o tl a g e ?

F a n b e tl t e n s i o n i n c o r r e c t ?

A ri lf o w i s n o t c ri c u l a it o n t h r o u g h r a d i a t o r ?

D o o r s o p e n ?

E x h a u s t l e a k i n g ?

t

H i g h e m p c o o l a n t e r t u r e il g h t i s o n .

O

O v v e e r r c s r p a e n e k d il il g g h h t t i i s s o o n .

n .

G e n e r a t o r b e i n g o v e r l o a d e d ?

T h e r m o s t a t f a li u r e ?

A ri i n t a k e b l o c k e d ?

T e m p e r a t u r e s w ti c h f a li u r e ?

N o o r l o w F u e l ?

C o n t r o ll e r n e e d s t o b e c a il b r a t e d ?

R P M e n g i n e s p e e d t o o h i g h ?

G o v e r n o r a c t u a t o r n e e d s t o b e a d j u s t e d ?

G o v e r n o r c o n t r o ll e r n e e d s t o b e a d j u s t e d ?

E n g i n e C o n t r o ll e r n e e d s t o b e c a il b r a t e d ?

L o s s o n .

o f M P U il g h t ( s ) o r

M a g n e it c p i c k u p o u t o f a d j u s t m e n t ?

M a g n e it c p i c k u p d ri t y ?

S o l u t i o n

F i ll o li l e v e .l

R e p l a c e o li p r e s s u r e s e n d i n g u n i .t

R e f e r t o d e a l e .r

I n s p e c /t r e p a ri w ri e .

F i ll c o o l a n t l e v e .l

R e p l a c e s e n d i n g u n i .t

R e p l a c e / c h a r g e b a tt e r y .

T i g h t e n / r e p l a c e f a n b e l .t

C l e a n / r e p a ri r a d i a t o r g r li .l

C l o s e d o o r s .

R e p l a c e / r e p a ri g a s k e t s o r f a u tl y p a r .t

C h e c k / r e d u c e l o a d .

R e p l a c e t h e r m o s t a .t

C l e a r a ll a ri i n t a k e s .

R e p l a c e t e m p e r a t u r e s w ti c h .

F i ll f u e l l e v e .l


A d j u s t R P M .

A d j u s t g o v e r n o r a c t u a t o .r

A d j u s t g o v e r n o r c o n t r o ll e .r


A d j u s t m a g n e it c p i c k u p .

C l e a n m a g n e it c p i c k u p .


EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO.

PART NO. PART NAME

1

4

3

2 *

2 *

12345

12347

12348

12349

QTY. REMARKS

BOLT ....................... 1 .... INCLUDES ITEMS W/ *

WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY

WASHER, 3/8 IN. .... 1 .... MQ-45T ONLY

HOSE .................... A/R .. MAKE LOCALLY

BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

( * , #, + , %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTE

PART NO. Column

without notice. Multiquip does not

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

Numbers Used - Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

QTY. Column

Numbers Used - Item quantity can be indicated by a number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clarified in the “Remarks”

Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit - All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break - Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”

“S/N XXXX AND ABOVE”

“S/N XXXX TO S/N XXX”

Specific Model Number Use - Indicates that the part is used only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY”

“NOT USED ON XXXX”

“Make/Obtain Locally” - Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” - Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.


DCA-300SSK — SUGGESTED SPARE PARTS

DCA-300SSK W/KOMATSU SA6D125E-2/ SAA6D125E-2

1 to 5 Units

Qty.

P/N Description

10 .............. 6125817032 .....................AIR FILTER, INNER & OUTER

10 .............. 6003118321 .....................FUEL FILTER

10 .............. 6002111231 .....................OIL FILTER

5 ................ 6004111151 .....................CARTRIDGE, CORROSION RESISTOR

3 ................ 0810105400 .....................FUEL FILTER, FUEL TANK

2 ................ xxxxxxxxxx .....................ENGINE FAN BELT

1 ................ 6008155390 .....................SWITCH, STARTER ................................. UP TO S/N 370163

5 ................ 615 ...................................KEY SET, STARTER SWITCH (2) ........... UP TO S/N 370163

1 ................ 6152611520 .....................RADIATOR HOSE (UPPER) ..................... UP TO S/N 3708296

1 ................ 6152611531 .....................RADIATOR HOSE (LOWER) .................... UP TO S/N 3708296

1 ................ 6152611530 .....................RADIATOR HOSE (UPPER) ..................... S/N 3708297 AND ABOVE

1 ................ 6152621540 .....................RADIATOR HOSE (LOWER) .................... S/N 3708297AND ABOVE

1 ................ 0605505030 .....................FUEL CAP

1 ................ 0601850590 .....................KEY, FUEL CAP

1 ................ 0601820625 .....................AUTOMATIC VOLTAGE REGULATOR

1 ................ 0601810072 .....................PILOT LAMP

2 ................ 0601810261 .....................BULB, PILOT LAMP

1 ................ 23S0311150M ..................CAP, RADIATOR ...................................... UP TO S/N 3708296

1 ................ 0602122200 .....................UNIT, OIL PRESSURE

1 ................ 0602123206 .....................UNIT, WATER TEMPERATURE

1 ................ 0602121052 .....................CHARGING AMMETER

1 ................ 0601804887 .....................CIRCUIT BREAKER, OUTPUT

............................................................TERMINAL,KM51, 265V 20A ................... UP TO S/N 3706720


............................................................TERMINAL,QOU120B 20A ...................... TO S/N 3706721 ABOVE


............................................................TERMINAL,KM52, 265V 50A ................... UP TO S/N 3706720


............................................................TERMINAL,QOU250B 50A ...................... TO S/N 3706721 ABOVE

NOTE

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


GENERATOR ASSY.

DCA-300SSK GENERATOR ASSY.



GENERATOR ASSY.

NO.

PART NO.

1 C2110100302

8 *

9 *

10 *

11 *

12 *

13 *

14 *

15

5 *

5 *

6 *

7 *

2 *

3 *

4 *

5 *

0012116040

0042516000

0012112040

0042512000

C2130100103

0226200430

8201323004

0223300140

8201323103

0221200350

0010110035

0041210000

C2132200003

0226000275

0225000500

0017106016

0601842401

0601823282

0018205020

0040005000

0041205000

8201070002

8201611004

C3164200004

8201015003

0012116045

0042616000

0601000209

C3112500004

0071906315

8201614003

0601850144

C3154000002

C3138000003

0012110080

0042610000

0041210000

0017112045

C3154300104

C3154300004

0010106060

0040006000

0041206000

33

33

34

35

30

31

32

33

36

37

37

37

26

27

28

29

23

24

25

25

19

20

21

22

16

17

18

18

PART NAME QTY.

REMARKS

ROTOR ASSY. ............................................... 1 ......... INCLUDES ITEM W/ *

FIELD ASSY.

1

RESISTOR ...................................................... 2 ......... 80W 300K OHM

RECTIFIER ..................................................... 1 ......... RM50TC-24

HEX. SOCKET HEAD CAP SCREW 2

LOCK WASHER

PLAIN WASHER

FAN

COUPLING DISK

1

12

2

2

WASHER, COUPLING HUD 1

BALANCING PLATE ....................................... 1 ......... PURCHASE AS SET OF 1-14

HEX. HEAD BOLT

LOCK WASHER

10

10

BALANCING WEIGHT KIT

BEARING FLANGE

1

1

BEARING ........................................................ 1 ......... 6315DDUC3

COUPLING RING 1

HEX. HEAD BOLT

LOCK WASHER

HEX. HEAD BOLT

LOCK WASHER

6

6

12

12

STATOR ASSY.

RUBBER SEAL

CLAMPER

RUBBER SEAL

CLAMPER

RUBBER SEAL

HEX. HEAD BOX

PLAIN WASHER

COVER

RUBBER SEAL

RUBBER SEAL

HEX. HEAD BOLT

GROMMET

END BRACKET

FIELD ASSY. EXCITER

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER

HEX. HEAD BOLT

COVER, BEARING

GASKET, BEARING

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER

1

1

1

1

1

1

2

2

1

2

1

6

1

1

1

4

4

4

8

1

1

4

4

4


GENERATOR ASSY.




GENERATOR ASSY.(CONT)

42

42

43

44

44

40

41

41

42

NO.

PART NO.

38 C3154400003

39

40

0017106016

0012112035

0042512000

C3132300003

C3132300014

0010106030

0041206000

0600815000

0605000012

0030020000

0040020000

PART NAME

SUCTION COVER

HEX. HEAD BOLT

HEX. HEAD BOLT

QTY.

REMARKS

1

8

16

LOCK WASHER 16

COVER, FAN ................................................... 1 ......... S/N3691259 TO 3692208

COVER, FAN ................................................... 1 ......... S/N3692209 AND ABOVE

HEX. HEAD BOLT 1

PLAIN WASHER 1

NUT ................................................................. 1 ......... S/N3692209 AND ABOVE

RUBBER SUSPENSION

HEX. NUT

2

4

LOCK WASHER 4


CONTROL BOX ASSY.

DCA-300SSK CONTROL BOX ASSY.



CONTROL BOX ASSY.

8

8

8

7

8

6

6

4

5

3

4

1

2

NO.

PART NO.

1 C2214000102

PART NAME QTY.

REMARKS

CONTROL BOX .............................................. 1 ............... S/N 3691259 TO 3706720

C2214001502

0601806134

CONTROL BOX .............................................. 1 ............... S/N 3706721 AND ABOVE

CURRENT TRANSFORMER .......................... 3 ............... CT-5MR500/5A

0027106016

0601807373

0601807513

0601802525

MACHINE SCREW 6

CIRCUIT BREAKER,XS800NS800A .............. 1 ............... UP TO 3706720

CIRCUIT BREAKER, S6G800A ...................... 1 ............... S/N 3706721AND ABOVE

HANDLE, CIRCUIT BREAKER ....................... 1 ............... S/N 3691259 TO 3706720

C2214600004 BRACKET, CIRCUIT BREAKER .................... 2 ............... S/N 3691259 TO 3706720

C2261600204 BRACKET, CIRCUIT BREAKER .................... 1 ............... S/N 3706721AND ABOVE

0017108020 HEX. HEAD BOLT

0021008045 MACHINE SCREW

4

4

0030008000 HEX. NUT ....................................................... 4 ............... S/N 3691259 TO 3706720

0040008000 LOCK WASHER .............................................. 4 ............... S/N 3691259 TO 3706720

0041208000 PLAIN WASHER ............................................. 4 ............... S/N 3691259 TO 3706720

9 0601820625 AUTOMATIC VOLTAGE REGULATOR ............. 1 ............... NTA-5A-2T

10 0027105016 MACHINE SCREW 4

11 0601820892 OVER CURRENT RELAY ............................... 1 ............... TH-N20HZKP

12 0027104016 MACHINE SCREW

13 C2274000103 CHANGE-OVER BOARD VOLTAGE

14 8201852104 CHANGE TERMINAL

15 0017108030 HEX. HEAD BOLT

2

1

10

20

16 C2277200004 TERMINAL PLATE

17 8201853104 CHANGE PLATE

18 8201852504 HEX. HEAD BOLT

19 0801830704 HEX. HEAD BOLT

13

13

3

6

20 0040012000 LOCK WASHER

21 0041412000 PLAIN WASHER

26

26

22 0017110030 HEX. HEAD BOLT 4

23 C2261500003 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 1337508 TO 3691258



23 C2261500713 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 3701674 AND ABOVE

24 0017108020 HEX. HEAD BOLT .......................................... 4

25 6008151252 EMERGENCY RELAY .................................... 1 .............. S/N 3696507 TO 3701673

......................................................................................... REPLACES 0602200446

26 0017106016 HEX. HEAD BOLT .......................................... 4 .............. S/N 3696507 TO 3701673

27 0601824542 RELAY ............................................................ 2 .............. HH62SDC24V

28 0027103010 MACHINE SCREW ......................................... 4


CONTROL BOX ASSY. (CONT)





NO.

PART NO.

PART NAME QTY.

REMARKS

29 0602201911 UNIT, BATTERY SENSOR ..........................1 ........ C7038A-00-00

30 0027106016 MACHINE SCREW 1

31 C2224000503 CONTROL PANEL 1

32 C2224000404 CONTROL PANEL ......................................1 ........ S/N3691259 TO 3706720

32 C2224001504 CONTROL PANEL ......................................1 ........ S/N3706721 AND ABOVE

33 0605011211 PIN 2

34 0601807622 FREQUENCY METER ................................1 ........ RSC-80F 220V 45-65HZ

35 0601806979 AC AMMETER ...........................................1 ........ RSS-80 0-500A 0-1000A

36 0601801040 CHANGE-OVER SWITCH, AMMETER ......1 ........ SL-2AS

37 0601806887 AC VOLTMETER ........................................1 ........ RSR-80 0-600V

38 0601801041 CHANGE-OVER SWITCH, VOLTMETER ...1 ........ SL-2VS

39 0601810072 PILOT LAMP ..............................................1 ........ LP-132DC 220V

39 0601810261 BULB ..........................................................1 ........ CT-13W

40 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ........1 ........ RA20A2SE102BJ 2W 1K OHM

41 0601840121 KNOB 1

42 0601810161 PANEL LIGHT .............................................1 ........ V325070

42 0601810214 BULB

43 0207004000 HEX. NUT

1

2

44 0601830710 SWITCH, PANEL LIGHT 1

45 C2214600104 COVER .......................................................1 ........ S/N3691259 TO 3706720

46 0027105016 MACHINE SCREW .....................................4 ........ S/N3691259 TO 3706720

47 C9221100004 HEX. HEAD BOLT 2

47 0040008000 LOCK WASHER


2

2

47 505015300 SNAP RING ................................................2 ........ REPLACES 0080200007

48 0017108040 HEX. HEAD BOLT 4

49 3871824004 STOPPER, CONTROL PANEL


1

1

51 0605010502 SNAP PIN

52 C2214500004 COVER, CONTROL BOX

53 0017108020 HEX. HEAD BOLT

54 C2214300004 SIDE PANEL, CONTROL BOX

55 0017108020 HEX. HEAD BOLT

56 C2214400004 PANEL, CONTROL BOX

57 0017108020 HEX. HEAD BOLT

58 0017110025 HEX. HEAD BOLT

1

1

8

1

4

1

8

4

59 0601823861 ENGINE STOP UNIT, MSA9014 .................1 ........ S/N3696507 TO 3701673

60 0027104015 MACHINE SCREW .....................................2 ........ S/N3696507 TO 3701673







76

77

78

73

73

74

75

70

71

72

72

66

67

68

69

65

65

65

65

63

63

63

64

NO.

PART NO.

61 0601823240

62

62

62

63

0021004030

0040004000

0041204000

0601802149

0601802149

0601806671

0601802218

0027103020

0601823732

0601827655

0601823109

0601824400

PART NAME QTY.

REMARKS

RECTIFIER, DE4503 ..................... 4 .............. S/N 3696507 TO 3701673

MACHINE SCREW ........................ 2 .............. S/N 3696507 TO 3701673

LOCK WASHER ............................. 2 .............. S/N 3696507 TO 3701673

PLAIN WASHER ............................ 2 .............. S/N 3696507 TO 3701673

FUSE, 10A ..................................... 1 .............. S/N 3696507 TO 3701673

FUSE (RIGHT), 10A ...................... 1 .............. S/N 3701674 AND ABOVE

FUSE (LEFT), 15A ......................... 1 .............. S/N 3701674 AND ABOVE

HOLDER, FUSE ............................ 1 .............. S/N 3701674 AND ABOVE

MACHINE SCREW ........................ 2 .............. S/N 3701674 AND ABOVE

RELAY ........................................... 1 .............. S/N 3696507 TO 3699681

RELAY ........................................... 1 .............. S/N 3699682 AND ABOVE

SOCKET ........................................ 1 .............. S/N 3696507 AND ABOVE

HOLDER ........................................ 1 .............. S/N 3696507 AND ABOVE

0027104020

0601823706

0027104015

0601815402


RELAY, HE1ADC24V ..................... 1 .............. S/N 3696507 AND ABOVE


TERMINAL BOARD, TS144P ......... 1 .............. S/N 3696507 AND ABOVE

0027104020 MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE

ECU9988N300/400 CONTROLLER ............................... 1 .............. REPLACES 0601827396 & 0602202545

0601831340

0601830765

SWITCH, 82608DPDT ................... 1 .............. S/N 3696507 TO 3700240

SWITCH, S303T ............................ 1 .............. S/N 3700241 AND ABOVE

DYNT11200

0602202470

SPEED SENSOR .......................... 1 .............. S/N 3696507 AND ABOVE

SEALED CABLE ............................ 1 .............. S/N 3696507 AND ABOVE

DYN110654000024 CONTROLLER ............................... 1 .............. S/N 3701674~; REPLACES 0602202598

0027104020 MACHINE SCREW ........................ 4 .............. S/N 3701674 ABOVE

0601840009

C3262600004

0017106015

RHEOSTAT, RA20A2SE5028 ......... 1 .............. S/N 3701674 ABOVE

BRACKET ...................................... 1 .............. S/N 3701674 ABOVE

HEX. HEAD BOLT ......................... 2 .............. S/N 3701674 ABOVE


DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)


DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

34

35

36

37

30

31

32

33

38

39

40

26

27

28

29

22

23

24

25

17

18

19

20

21

13

14

15

16

9

10

11

12

7

8

5

6

2

3

4

NO.

PART NO.

1 6155009100

PART NAME QTY.

REMARKS

ENGINE, KOMATSU SA6D 125E-2 .............. 1 ..........S/N 3691258 AND BELOW

....................................................................................REPLACES C2924200014

6125817032 ELEMENT, AIR CLEANER ............................ 1 ..........REPLACES 0602040156

6002111231 CARTRIDGE, OIL FILTER ............................ 1 ..........REPLACES 0602041146

6003118293 CARTRIDGE, FUEL FILTER ......................... 1 ..........REPLACES 0602042146

6004111151

0602040678

8185112004

0010118060

0030018000

0040018000

0041218000

0605000011

CARTRIDGE, CORROSION RESISTOR ...... 1 ..........REPLACES 0602045143

DUST SENSOR ............................................ 1 ..........REX01-8126

ENGINE FOOT .............................................. 1 ..........S/N 3691258 AND BELOW

HEX. HEAD BOLT ......................................... 2 ..........S/N 3691258 AND BELOW

HEX. NUT ..................................................... 2 ..........S/N 3691258 AND BELOW

LOCK WASHER ............................................ 2 ..........S/N 3691258 AND BELOW

PLAIN WASHER ........................................... 4 ..........S/N 3691258 AND BELOW

RUBBER SUSPENSION 2

0030016000 HEX. NUT

0040016000 LOCK WASHER


0030012000 HEX. NUT

0040012000 LOCK WASHER

0041212000 PLAIN WASHER

8195123104 BRACKET, RADIATOR

4

4

6152619720 RADIATOR .................................................... 1 ..........REPLACES 0602011946

6152619170 RUBBER SHEET .......................................... 2 ..........REPLACES 0605000490

4

4

4

8

2



2

2

6152611520 RADIATOR HOSE ......................................... 1 ..........REPLACES 0602014513



0728100809 HOSE BAND ................................................. 6 ..........REPLACES 0602014067



0802081003C RESERVE TANK ........................................... 1 ..........REPLACES 0802081003

0802010900 CAP, RESERVE TANK .................................. 1 ..........REPLACES 0602010900

C231710003 BRACKET, RESERVE TANK


1

2

0199601800 HOSE

0193601300 HOSE

0193600500 HOSE

0194100800 HOSE

1

1

1

1

0605515170 HOSE BAND

C2327100003 BREATHER PIPE


5

1

2


DCA-300SSK ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

ENGINE & RADIATOR ASSY. (UP TO S/N3697258)


DCA-300SSK ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

49

50

51

45

46

47

48

NO.

PART NO.

41

42

43

44

0603320112

0038408000

0268200700

0605515132

C2358300103

0017110020

C2358300003

0017108020

0010016030

0040016000

0041216000

PART NAME

U BOLT

HEX. NUT

HOSE

HOSE BAND

CLAMPER ROD

HEX. HEAD BOLT

CLAMPER ROD

HEX. HEAD BOLT

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER

1

1

1

1

1

1

2

QTY.

REMARKS

1

2

1

2


DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 TO 3708296)

ENGINE & RADIATOR ASSY. (S/N3691259 TO S/N 3708296)


DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 TO 3708296)

ENGINE & RADIATOR ASSY. (S/N3691259 TO S/N 3708296)

NO.

PART NO.

1 C2924200154

29

30

31

32

25

26

27

28

20

21

22

24

16

17

18

19

12

13

14

15

8

9

10

11

4

5

6

7

1

2

3

40

41

42

43

44

45

46

36

37

38

39

33

34

34

35

C2925200014

6125817032

6002111231

6003118321

6004111151

0602040678

0605000011

0030016000

0040016000

6152619720

615261970

0010112055

0030012000

0040012000

0041212000

8195123104

0017112025

0017110025

0602014549

6152611531

0726120911

0728100809

0728100197

0802081003

0602010900

C2317100003

0017108020

0199901800

0193601300

0193600500

0194100800

0605515170

C2327100003

C2327100012

0017108020

0603320112

0207008000

0268200700

0605515132

C2358300103

0017110020

C2358300003

0017108020

0010016030

0040016000

0041216000

PART NAME QTY.

REMARKS

ENGINE ................................................................. 1 .......... REPLACES S/N 3691259 TO 3701673

ENGINE ................................................................. 1 .......... S/N3701674 TO 3708269

ELEMENT, AIR CLEANER, INNER/OUTER

CARTRIDGE, OIL FILTER

1

1

CARTRIDGE, FUEL FILTER

CARTRIDGE, CORROSION RESISTOR

1

1

DUST SENSOR ..................................................... 1 .......... REX018126

RUBBER SUSPENSION ....................................... 2 .......... EA1012

HEX. NUT

LOCK WASHER

4

4

RADIATOR ............................................................. 1 .......... REPLACES 0602011946

RUBBER SHEET ................................................... 2 .......... REPLACES 0605000490

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER

PLAIN WASHER

4

4

4

8

BRACKET, RADIATOR

HEX. HEAD BOLT

2

2

HEX. HEAD BOLT 2

RADIATOR HOSE ................................................. 1 .......... REPLACES 6152611520



HOSE BAND .......................................................... 6 .......... REPLACES 0602014056

HOSE BAND .......................................................... 2 .......... REPLACES 0602014058

RESERVE TANK

CAP, RESERVE TANK

BRACKET, RESERVE TANK

HEX. HEAD BOLT

HOSE

HOSE

HOSE

HOSE

1

1

1

2

1

1

1

1

HOSE BAND 5

BREATHER PIPE ................................................... 1 .......... S/N3691259 TO 3705209

BREATHER PIPE ................................................... 1 .......... S/N3705210 TO 3708269

HEX. HEAD BOLT 2

U BOLT

HEX. NUT

HOSE

HOSE BAND

1

2

1

2

CLAMPER ROD

HEX. HEAD BOLT

CLAMPER ROD

HEX. HEAD BOLT

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER

1

2

1

1

1

1

1


DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)




NO.

PART NO.

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

28

29

29

8

9

10

11

6

7

4

5

2

3

1-4

1-5

1

1-1

1-2

1-3

C2924200194

6125817032

6002111231

6003118321

6004111151

0602040678

0605000011

0030016000

0040016000

6152629101

6995619230

0010120070

0030020000

004002000

0041220000

C2311100504

0010112025

0040012000

0041212000

0017110025

6152611530

6125621540

0726120911

0728100809

0728100909

0728100197

6152124380

6152124410

6152124420

0602014900

6152124490

0802081003

0602010900

C2317100304

02292 00550

PART NAME QTY.

REMARKS

ENGINE ............................................................. 1 .......... KOMATSU SAA6D125E-2

ELEMENT, AIR CLEANER ................................. 1 .......... REPLACES 06020 40145

CARTRIDGE, OIL FILTER ................................. 1 .......... REPLACES 06020 41146

CARTRIDGE, FUEL FILTER .............................. 1 .......... REPLACES 06020 42146

CARTRIDGE, COROSION RESISTOR ............. 1 .......... REPLACES 06020 45143

SENSOR, DUST REX01-8126 1

SUSPENSION, RUBBER EA1012

NUT, HEX

2

4

WASHER, SPRING 4

RADIATOR ........................................................ 1 .......... REPLACES 06020 12706

SHEET, RUBBER ............................................... 2 .......... REPLACES 06050 00085

BOLT, HEX HEAD 4

NUT, HEX

WASHER, SPRING

WASHER, PLAIN

BRACKET, RADIATOR

8

4

8

2

BOLT, HEX HEAD

WASHER, SPRING

WASHER, PLAIN

BOLT, HEX HEAD

2

2

2

2

HOSE, RADIATOR ............................................. 1 .......... REPLACES 06020 14539



HOSE BAND ...................................................... 6 .......... REPLACES 06020 14067



PIPE, RADIATOR ............................................... 1 .......... REPLACES 06020 13257





TANK, RESERVE 1

CAP, RESERVE TANK

BRACKET, RESERVE TANK

CUSHION, RUBBER

1

1

1







NO.

PART NO.

42

43

44

45

38

39

40

41

46

47

48

49

50

34

35

36

37

30

31

32

33

00171 06025

00171 08020

01999 01900

01936 02000

06055 15170

01936 00560

06055 15170

02691 00650

C23271 00103

00171 08020

06033 20112

02070 08000

02682 00700

06055 15132

C23583 01003

00171 10020

C23583 00003

00171 08020

00100 16030

00400 16000

00412 16000

PART NAME

BOLT, HEX HEAD

BOLT, HEX HEAD

HOSE

HOSE

HOSE BAND

HOSE

HOSE BAND

HOSE

PIPE, BREATHER

BOLT, HEX HEAD

UBOLT

NUT, HEX HEAD

HOSE

HOSE BAND

ROD, CLAMPER

BOLT, HEX HEAD

ROD, CLAMPER

BOLT, HEX HEAD

BOLT, HEX HEAD

WASHER, SPRING

WASHER, PLAIN

QTY.

REMARKS

1

2

1

2

1

2

1

2

1

1

1

1

1

1

1

2

1

1

1

1

2


ENGINE OPERATING PANEL ASSY.

DCA-300SSK ENGINE OPERATING PANEL ASSY.

S/N3701674~

UP TO S/N3701673


DCA-300SSK ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

31

32

33

34

35

36

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

12

13

13

14

8

9

10

11

7

7

5

6

5

5

4

5

2

3

1

2

NO.

PART NO.

1 C2352100203

1 C2352100213

C2352100223

0017106016

0017106015

0207006000

0602101000

0021008080

0030008000

0040008000

0041208000

0800250300

C2484000003

C2484000303

0017110025

8192183004

0010010035

0030010000

0041210000

C2355300404

C2355300414

C2355300104

0602180106

0030008000

0207006000

0041206000

0041206000

505015300

0601830448

0601831557

6008153730

0602120054

0602120156

0602122060

0602122200

0602123061

0602123206

0602121052

0602125060

0602115014

0601830710

0806410000

6008155390

615

PART NAME QTY.

REMARKS

OPERATING PANEL .......................... 1 ......... S/N 3696506 AND BELOW

OPERATING PANEL .......................... 1 ......... S/N 3696507 TO 3701673

OPERATING PANEL .......................... 1 ......... S/N 3701674 AND ABOVE

HEX. HEAD BOLT .............................. 8 ......... S/N 3701673 AND BELOW

HEX. HEAD BOLT .............................. 8 ......... S/N 3701674 AND ABOVE

HEX. NUT 4

BATTERY SWITCH

MACHINE SCREW

HEX. NUT

LOCK WASHER

2

2

1

2

PLAIN WASHER 2

THROTTLE HANDLE ......................... 1 ......... S/N 3701673 AND BELOW

SET FRAME ...................................... 1 ......... S/N 3701674 TO 3708296

SET FRAME ...................................... 1 ......... S/N 3708297

HEX. HEAD BOLT 2

LINK, GOVERNOR ROD .................... 1 ......... S/N 3701673 AND BELOW

HEX. HEAD BOLT .............................. 1 ......... S/N 3701673 AND BELOW

HEX. NUT ........................................... 1 ......... S/N 3701673 AND BELOW

PLAIN WASHER ................................ 2 ......... S/N 3701673 AND BELOW

GOVERNOR ROD .............................. 1 ......... S/N 1337508 TO 3691258

GOVERNOR ROD .............................. 1 ......... S/N 3691259 TO 3701673

GOVERNOR ROD .............................. 1 ......... S/N 3701673 AND BELOW

BALL JOINT ....................................... 2 ......... S/N 3701673 AND BELOW





SNAP PIN .......................................... 2 ......... UP TO S/N3701673; REPLACES 0605010502

PREHEAT BUTTON, AH25FB10 ........ 1 ......... S/N3696507~

EMERGENCY STOP BUTTON .......... 1 ......... S/N3701674~; AR22V2R01R

PREHEAT LAMP ................................ 1 ......... REPLACES 0602102055

TACHOMETER ................................... 1 ......... 25000-KX4110

CABLE, TACHOMETER ..................... 1 ......... 62500-KA4210L=3000

OIL PRESSURE GAUGE ................... 1 ......... 42000-KX1410

UNIT, OIL PRESSURE ....................... 1 ......... 53000-AC0101

WATER TEMPERATURE GAUGE ...... 1 ......... 40000-KX0910

UNIT, WATER TEMPERATURE .......... 1 ......... 51400-KS0600

CHARGING AMMETER ..................... 1 ......... 43000-KV0300

FUEL GAUGE .................................... 1 ......... 41000-KW0110

MONITOR ........................................... 1 ......... V337660-0000

ENGINE SPEED SWITCH, S301T .... 1 ......... S/N3701674~

STOP BUTTON .................................. 1 ......... UP TO S/N3701673; REPLACES 0602104045

STARTER SWITCH ............................ 1 ......... UP TO S/N3701673; REPLACES 0602100049

KEY, STARTER SWITCH ................... 1 ......... UP TO S/N3701673; REPLACES 0602104045


OUTPUT TERMINAL ASSY.

DCA-300SSK OUTPUT TERMINAL ASSY.

UP TO S/N3691258

S/N3691259~



16

17

17

17

14

15

16

16

18

19

20

20

12

12

13

14

10

10

11

11

9

9

8

8

8

8

8

8

6

7

4

5

2

3


NO.

PART NO.

1 C2231700203

1 8221860203

PART NAME QTY.

REMARKS

SET BOARD, OUTPUT TERMINAL ................ 1 ......... S/N 3708296 AND BELOW

SET BOARD, OUTPUT TERMINAL ................ 1 ......... S/N 3708297 AND ABOVE

0801830404

0801830904

0039320000

0040020000

0041420000

3501860604

0019108040

0042308000

0042408000

0019110050

004231000

004241000

0601804887

0601808803

0601805840

0601808804

C1261600204

C3261600704

0223300200

0221200150

0017106020

0601812597

0601812598

0601811034

0027104015

0030004000

0041204000

C2237100403

C2237101103

C2237101103

0019112045

0042412000

0805009804

0805015604

OUTPUT TERMINAL

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER

PLAIN WASHER

TERMINAL PLATE

16

24

32

3

8

8

HEX. HEAD BOLT ........................................... 5 ......... S/N 3708296 AND BELOW

LOCK WASHER .............................................. 5 ......... S/N 3708296 AND BELOW

PLAIN WASHER ............................................. 5 ......... S/N 3708296 AND BELOW

BOLT, HEX HEAD ........................................... 5 ......... S/N 3708297 AND ABOVE

WASHER SPRING .......................................... 5 ......... S/N 3708297 AND ABOVE

WASHER PLAIN ............................................. 5 ......... S/N 3708297 AND ABOVE

CIRCUIT BREAKER, KM-51 265V 20A .......... 2 ......... S/N 3691259 TO 3706720

CIRCUIT BREAKER, QOU120B 20A ............. 2 ......... S/N 3706721~; REPL. 0601805313

CIRCUIT BREAKER,KM-52 265V 50A ........... 3 ......... S/N 3691259 TO 3706720

CIRCUIT BREAKER,QOU250B 50A ............... 3 ......... S/N 3706721 AND ABOVE

BRACKET, CIRCUIT BREAKER ..................... 1 ......... S/N 3691259 TO 3706720

BRACKET, CIRCUIT BREAKER ..................... 1 ......... S/N 3706721AND ABOVE

RUBBER CUSHION ........................................ 1 ......... S/N 3691259 TO 3706720

RUBBER CUSHION ........................................ 1 ......... S/N 3706721AND ABOVE

HEX. HEAD BOLT 2

RECEPTACLE, 125 V, 20 AMP ....................... 2 ......... S/N 1337508 TO 3691258

RECEPTACLE, 125 V, 20 AMP ....................... 2 ......... S/N 3691259 AND ABOVE

RECEPTACLE ................................................. 3 ......... REPLACES 0601812565

MACHINE SCREW

HEX. NUT

10

10

PLAIN WASHER 10

COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 1337508 TO 3691258

COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 3691259 AND ABOVE


HEX. HEAD BOLT

PLAIN WASHER

2

2

RUBBER WASHER 2

RUBBER WASHER ......................................... 2 ......... S/N 3708297 AND ABOVE




UP TO S/N3691258

S/N3691259~




30

31

32

34

26

27

28

29

35

36

23

23

24

25

NO.

PART NO.

21 020501200

22

23

0845043704

C2237100504

C2237100514

C2237101204

0017108020

C0237101504

0805015604

0845054204

0017110040

0601815324

0027104020

0601850275

0601851780

C2237101504

C2237400104

0017106020

PART NAME

HEX. NUT

QTY.

REMARKS

2

SPRING 2

COVER ............................................................ 1 ......... S/N 1337508 TO 3691258

COVER ............................................................ 1 ......... S/N 3691259 AND ABOVE


HEX. HEAD BOLT 9


RUBBER WASHER ......................................... 1 ......... S/N 3691259 AND ABOVE

COLLER .......................................................... 2 ......... S/N 3691259 AND ABOVE

HEX. HEAD BOLT ........................................... 2 ......... S/N 3691259 AND ABOVE

TERMINAL BOARD, TS22P ............................ 1 ......... S/N3696507 AND ABOVE

MACHINE SCREW ......................................... 2 ......... S/N3696507 AND ABOVE

GROMMET ..................................................... 1 ......... S/N3696507 AND ABOVE

GROMMET ..................................................... 2 ......... S/N3700674 AND ABOVE


BRACKET 1

BOLT, HEX HEAD ........................................... 2 ......... S/N 3708297 AND ABOVE


ACTUATOR ASSY. (S/N3701674~)

DCA-300 SSK ACTUATOR ASSY.


DCA-300 SSK ACTUATOR ASSY.

ACTUATOR ASSY. (S/N 3701674~)

9

9

7

8

5

6

5

5

9

10

10

10

4

5

2

3

NO.

PART NO.

1 DYNC110240000024

DYNC182

C1356200004

0012310030

0010306035

0207006000

0040006000

0041206000

0602211091

0602180190

0602211092

0010106025

0207006000

0041206000

0010106025

0207006000

0041206000

PART NAME QTY.

REMARKS

ACTUATOR ....................................... 1 ............. REPLACES 0602150091

LEVER ............................................. 1 ............. REPLACES 0602211090

BRACKET, ACTUATOR 1

HEX. HEAD BOLT

HEX. HEAD BOLT

4

4

HEX. NUT

LOCK WASHER

PLAIN WASHER

ROD

BALL JOINT

HEX. NUT

HEX. HEAD BOLT

HEX. NUT

PLAIN WASHER

HEX.HEAD BOLT

HEX. NUT

PLAIN WASHER

4

4

4

1

2

2

1

1

1

1

1

4


BATTERY ASSY.

DCA-300 SSK BATTERY ASSY.


BATTERY ASSY.

11

12

13

14

7

8

9

10

15

16

17

5

6

3

4

NO.

PART NO.

1 0168614551

2 0805000804

3972250004

0805002904

0037808000

0040008000

0041208000

C2347600404

C2347600104

C2347600204

C2347600304

C2347200004

0010010030

0030010000

0845040414

0845041304

0602220204

PART NAME

BATTERY

BATTERY SHEET

BATTERY BAND

BATTERY BOLT

WING NUT

LOCK WASHER

PLAIN WASHER

BATTERY CABLE

BATTERY CABLE

BATTERY CABLE

BATTERY CABLE

EARTH CABLE

HEX. HEAD BOLT

HEX. NUT

TERMINAL CAP +

TERMINAL CAP -

BATTERY SENSOR

DCA-300 SSK BATTERY ASSY.

4

4

1

1

1

1

2

1

QTY.

REMARKS

2

2

2

2

1

2

2

2

1


MUFFLER ASSY.

DCA-300SSK MUFFLER ASSY.


DCA-300SSK MUFFLER ASSY.

8

9

7

7

7

7

6

6

6

6

5

5

4

5

MUFFLER ASSY.

2

3

NO.

PART NO.

1 C2331100002

0019210025

C2334000003

3 C2234000503

6150115751

7502356004

C1334200304

6150115751

0010312050

0030312000

0040012000

0041212000

0010112055

0030012000

0040012000

0041212000

C2331300004

0017108020

PART NAME

MUFFLER

QTY.

REMARKS

1

HEX. HEAD BOLT 4

EXHAUST PIPE .............................................. 1 ......... UP TO S/N 3708296

EXHAUST PIPE .............................................. 1 ......... S/N 3708297 AND ABOVE

GASKET ......................................................... 1 ......... REPLACES 0602320142

GASKET ......................................................... 1 ......... S/N 1337508 TO 3691258

GASKET ......................................................... 1 ......... S/N 3691259 TO S/N 3708296

GASKET ......................................................... 1 ......... S/N 3708297 ABOVE

HEX. HEAD BOLT

HEX. NUT

4

4

LOCK WASHER

PLAIN WASHER

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER

PLAIN WASHER

COVER

HEX. HEAD BOLT

4

8

4

4

4

8

2

4


FUEL TANK ASSY.

DCA-300SSK FUEL TANK ASSY.


DCA-300SSK FUEL TANK ASSY.

FUEL TANK ASSY.

21

22

22

23

18

19

20

21

14

15

16

17

10

11

12

13

7

8

9

10

5

6

4

4

2

3

1

2

NO.

PART NO.

1 C2364000303

C2364000313

0605505030

0601850590

0810105400

0264100485

0264100525

0605515079

0605503023

0802120604

0605501050

0602021155

0027104010

0022905015

8195523104

0805003414

0017108020

0037908000

0222100300

0130206000

3515512014

0603325011

0132006000

0845039604

0191302000

0191302300

0191302240

0191302800

0605515109

PART NAME QTY.

REMARKS

FUEL TANK ..................................................... 1 ......... S/N 1337508 TO 2691258

FUEL TANK ..................................................... 1 ......... S/N 2691259 AND ABOVE

CAP, FUEL TANK ............................................ 1 ......... REPLACES 0605505005

KEY, FUEL TANK ............................................ 1 ......... REPLACES 0601850505

FUEL FILTER 1

HOSE, FUEL GAUGE 1

HOSE, FUEL GAUGE ..................................... 1 ......... S/N 3708297 AND ABOVE

HOSE BAND 2

FUEL SENSOR ............................................... 1 ......... FF-9

PACKING 1

UNIT FUEL ...................................................... 1 ......... 52000-KA9810

PACKING ........................................................ 1 ......... 52391-KW3700

MACHINE SCREW ......................................... 5 ......... S/N 3691259 AND ABOVE

MACHINE SCREW ......................................... 5 ......... S/N 1337508 TO 2691258

TANK BAND 2

PAD, TANK BAND

HEX. HEAD BOLT

4

2

HEX. NUT

TANK SHEET

STREET ELBOW

DRAIN PIPE

2

6

1

1

VALVE ............................................................. 1 ......... BBS-77-15 PT1/2

PLUG 1

RUBBER SEAL 1

SUCTION HOSE ............................................. 1 ......... UP TO S/N 1337973

SUCTION HOSE ............................................. 1 ......... FROM S/N 1337974

RETURN HOSE .............................................. 1 ......... UP TO S/N 1337973

RETURN HOSE .............................................. 1 ......... FROM S/N 1337974

HOSE BAND 4


DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)

ENCLOSURE ASSY. (UP TO S/N 3708296)

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR

OF ORANGE. TO ORDER WITH DIFFERENT COLOR,

PLEASE ADD THE FOLLOWING LETTERS WITH THE PART

NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

THE SERIAL NUMBER MAY BE REQUIRED.




24

25

25

26

22

22

23

23

27

19

19

20

21

18

18

18

18

17

17

17

17

14

15

16

16

10

11

12

13

7

8

9

10

7

7

6

7

5

5

3

4

NO.

PART NO.

1

2

1

1

C2414000002

C2414000402

C2415000002

C3414100104

C2414100004

0019208020

C2414600004

C2494000004

0017108020

C2424000402

C2425000202

C2425000212

C2494100003

0019210025

C2424200003

C2424200104

C2494100104

0019208020

0845042703

0019208020

C2424200203

0019208020

C2434000102

C2434000112

0010114050

0030014000

0040014000

0041214000

0010114040

0030014000

0040014000

0041214000

C2444000302

C2494300204

0019210025

0017110025

C2444300004

C2494300004

C2444300203

C2494300304

0207008000

C2444300104

C2494300104

0017108020

0019208020

PART NAME QTY.

REMARKS

BASE .............................................................. 1 ......... S/N 1337508 TO 3691258

BASE .............................................................. 1 ......... S/N 3691259 TO 3701673

BASE .............................................................. 1 ......... S/N 3701674 TO 3708296

FLOOR PANEL 1

FLOOR PANEL

HEX. HEAD BOLT

1

14

DUCT 1

LINING ............................................................ 1 ......... TO S/N 3708296

HEX. HEAD BOLT 4

FRONT FRAME .............................................. 1 ......... S/N3691259 TO 3701673

FRONT FRAME .............................................. 1 ......... S/N3701674 TO 3705209

FRONT FRAME .............................................. 1 ......... S/N3705210 TO 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

HEX. HEAD BOLT 8

COVER, FRONT FRAME

COVER, FRONT FRAME

1

1

LINING

HEX. HEAD BOLT

FILLER BRACKET

HEX. HEAD BOLT

1

26

1

4

COVER, FRONT FRAME

HEX. HEAD BOLT

1

14

CENTER FRAME ............................................ 1 ......... UP TO S/N 1337973

CENTER FRAME ............................................ 1 ......... S/N 1337974 TO 3708296

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER

PLAIN WASHER

4

4

4

8

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER

PLAIN WASHER

REAR FRAME

LINING

HEX. HEAD BOLT

HEX. HEAD BOLT

4

3

1

1

8

16

8

8

COVER, REAR FRAME

LINING

1

1

DUCT .............................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

HEX. NUT

PANEL

LINING

HEX. HEAD BOLT

HEX. HEAD BOLT

15

1

1

6

14







NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE





54

54

55

55

56

56

53

53

53

54

52

53

53

53

50

50

51

51

48

48

49

50

44

45

46

47

42

43

43

44

38

39

40

41

35

35

36

37

31

32

33

34

NO.

PART NO.

28 C2444200003

29

30

C2444200103

8225147004

0037906000

B9114500104

0207006000

B9114000102

0021806016

0030006000

C3444700004

8195146304

0845050704

0207006000

0805011304

0805011204

0207006000

M9110100304

0845045004

M9110100304

0845045004

0019208020

0601850097

0025008025

C2464100002

C2494500004

0800251701

0025006016

0042306000

0042406000

C2464200002

C2494500104

0019208020

C2454200402

C2454200412

C2454200422

C2454200432

C2454200442

C2454200452

0019108065

0042308000

0042408000

C2454000203

C2494400404

C2454000303

C2494400604

PART NAME

DOOR, REAR FRAME

DOOR, REAR FRAME

WINDOW PLATE

HEX. NUT

DOOR POCKET

HEX. NUT

DOOR HANDLE

MACHINE SCREW

HEX. NUT

DOOR ROD

DOOR ROD

STAY

HEX. NUT

STOPPER, DOOR

STOPPER, DOOR

1

1

4

8

1

1

4

4

12

1

4

1

QTY.

1

1

2

REMARKS

HEX. NUT 4

HINGE ............................................................. 2 ......... REPLACES 0845047104

WASHER 2

HINGE ............................................................. 2 ......... REPLACES 0845047204

WASHER

HEX. HEAD BOLT

STOPPER

MACHINE SCREW

2

6

2

2

ROOF PANEL .................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

FILLER COVER

MACHINE SCREW

1

2

LOCK WASHER

PLAIN WASHER

2

2

ROOF PANEL .................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

HEX. HEAD BOLT 32

SPLASHER PANEL ......................................... 1 ......... UP TO S/N 1337973

SPLASHER PANEL ......................................... 1 ......... FROM S/N 1337974 TO 3691258

SPLASHER PANEL ......................................... 1 ......... S/N 3691259 TO 3696506

SPLASHER PANEL ......................................... 1 ......... S/N3696507 TO 3700673



HEX. HEAD BOLT 6

LOCK WASHER

PLAIN WASHER

6

6

SIDE DOOR .................................................... 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

SIDE DOOR .................................................... 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296







NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE





73

74

75

76

69

70

71

72

67

67

68

68

64

65

66

66

61

62

62

63

59

60

60

61

NO.

PART NO.

57 C2454000003

57

58

58

59

C2494400004

C2454000103

C2494400204

C2494400504

C2494400504

C2454300304

C2494400704

C2454300004

C2494400104

C2454300104

C2494400304

0207008000

B9114000002

0825007362

0021806016

0030006000

0845046904

0845045004

0845047004

0845045004

0019208020

0601850097

0021008025

0845031504

0600500090

0021106016

C2464500604

C2464500704

PART NAME QTY.

REMARKS

SIDE DOOR .................................................... 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

SIDE DOOR .................................................... 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

DUCT .............................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

DUCT .............................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

DUCT .............................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

DUCT .............................................................. 1 ......... TO S/N 3708296

LINING ............................................................ 1 ......... TO S/N 3708296

HEX. NUT 28

DOOR HANDLE

DOOR HANDLE

MACHINE SCREW

HEX. NUT

HINGE

WASHER

HINGE

WASHER

5

5

6

6

28

28

4

3

HEX. HEAD BOLT

STOPPER

MACHINE SCREW

CAP

25

8

8

14

EMBLEM

MACHINE SCREW

2

4

GUTTER ......................................................... 2 ......... S/N3707481 TO S/N3708296

GUTTER ......................................................... 2 ......... S/N3707481 TO S/N3708296


ENCLOSURE ASSY. (S/N 3708297~)

DCA-300SSK ENCLOSURE ASSY. (S/N 3708297~)




NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE





NO.

PART NO.

19

20

21

22

18

18

18

19

17

17

17

18

14

15

16

17

10

11

12

13

7

8

9

10

6

7

5

5

3

4

1

2

28

29

30

31

32

33

25

25

26

27

22

23

23

24

C24242 00203

00192 08020

C24340 01002

00101 14050

00300 14000

00400 14000

00412 14000

00101 14040

00300 14000

00400 14000

00412 14000

C24440 00302

C24943 00204

00192 10025

00171 10025

C24443 00004

C24140 01002

C34141 00104

C241410004

00192 08020

C24145 00204

C24940 00004

00171 08020

C24240 01702

C24941 00703

00192 10025

C24242 00003

C24242 00104

C24941 00104

00192 08020

08450 42703

00192 08020

C24943 00904

C24443 00803

C24943 00904

02070 08000

C24443 00104

C24943 00104

00171 08020

00192 08020

C24442 00003

C24442 00103

82251 47004

00379 06000

B91145 00104

02070 06000

PART NAME

BASE

PANEL, FLOOR

PANEL, FLOOR

BOLT, HEX HEAD

DUCT

LINING

BOLT, HEX HEAD

FRONT, FRAME

LINING

BOLT, HEX HEAD

COVER, FRONT FRAME

COVER, FRONT FRAME

LINING

BOLT, HEX HEAD

BRACKET, FILLER

BOLT, HEX HEAD

COVER, FRONT FRAME

BOLT, HEX HEAD

FRAME, CENTER

BOLT, HEX HEAD

NUT, HEX

WASHER, SPRING

WASHER, PLAIN

BOLT, HEX HEAD

NUT, HEX

WASHER, SPRING

WASHER, PLAIN

FRAME, REAR

LINING

BOLT, HEX HEAD

BOLT, HEX HEAD

COVER, REAR FRAME

LINING

DUCT

LINING

NUT, HEX

PANEL

LINING

BOLT, HEX HEAD

BOLT, HEX HEAD

DOOR, REAR FRAME

DOOR, REAR FRAME

PLATE, WINDOW

NUT, HEX

POCKET, DOOR

NUT, HEX

QTY.

3

1

1

4

16

1

8

8

8

8

4

4

1

14

1

4

1

26

1

4

1

1

1

8

4

1

1

1

1

14

1

1

2

12

1

1

1

4

6

14

1

1

1

15

1

1

REMARKS


ENCLOSURE ASSY. (S/N 3708297~





NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE





NO.

PART NO.

54

54

55

55

51

52

53

54

50

50

50

51

47

48

48

49

44

44

45

46

41

42

43

43

37

38

39

40

34

35

35

36

60

60

61

61

62

62

58

58

59

59

56

56

57

57

00254 08025

C24641 00402

C24945 00804

08002 51701

00250 06015

00423 06000

00424 06000

C24642 00502

C24945 00904

00192 08020

C24542 01402

00191 08065

00423 08000

00424 08000

C24540 02603

C24944 06004

B91140 00102

00218 06016

00300 06000

C34447 00004

81951 46304

08450 50704

02070 06000

08050 11304

08050 11204

02070 06000

08450 47104

08450 45004

08450 47204

08450 45004

00192 08020

06018 50097

C24540 02703

C24944 06204

C24540 02803

C24944 05504

C24540 03003

C24944 05804

C24543 02704

C24944 06104

C24543 02704

C24944 06104

C24543 02704

C24944 06104

C24543 02704

C24944 06104

PART NAME

HANDLE, DOOR

SCREW, MACHINE

NUT, HEX

ROD, DOOR

ROD, DOOR

STAY

NUT, HEX

STOPPER, DOOR

STOPPER, DOOR

NUT, HEX

HINGE

WASHER

HINGE

WASHER

BOLT, HEX HEAD

STOPPER

SCREW, MACHINE

PANEL, ROOF

LINING

COVER, FILLER

SCREW, MACHINE

WASHER, SPRING

WASHER, PLAIN

PANEL, ROOF

LINING

BOLT, HEX HEAD

PANEL, SPLASHER

BOLT, HEX HEAD

WASHER, SPRING

WASHER, PLAIN

DOOR, SIDE

LINING

DOOR, SIDE

LINING

DOOR, SIDE

LINING

DOOR, SIDE

LINING

DUCT

LINING

DUCT

LINING

DUCT

LINING

DUCT

LINING

QTY.

1

1

6

6

1

32

1

6

2

1

2

2

1

1

2

1

6

2

2

2

2

2

1

4

8

1

1

4

4

1

1

4

2

2

1

1

1

1

1

1

1

1

1

1

1

1

REMARKS







NUMBER:

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE





74

75

77

78

79

NO.

PART NO.

68

69

70

71

72

73

66

67

67

68

63

64

65

66

02070 08000

B91140 00002

08250 07362

00218 06016

00300 06000

08450 46904

08450 45004

08450 47004

08450 45004

00192 08020

06018 50097

00254 08025

08450 31504

06005 00090

00211 06016

C24645 00204

0019208020

C1425700004

0019206015

PART NAME

NUT, HEX

HANDLE, DOOR

HANDLE, DOOR

SCREW, MACHINE

NUT, HEX

HINGE

WASHER

HINGE

WASHER

BOLT, HEX HEAD

STOPPER

SCREW, MACHINE

CAP

EMBLEM

SCREW, MACHINE

GUTTER

HEX. HEAD BOLT

RADIATOR PANEL

HEX. HEAD BOLT

QTY.

5

25

8

8

15

2

16

6

6

5

28

4

3

28

4

2

4

1

4

REMARKS


RUBBER SEAL ASSY.

DCA-300SSK RUBBER SEAL ASSY.


DCA-300SSK RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

8

9

10

7

7

5

6

NO.

PART NO.

3

4

1

2

0228901250

0228901090

0228900650

0228901030

0229201400

0229201300

0228800705

0221200705

0228801200

0228100120

0228100510

PART NAME

RUBBER SEAL

RUBBER SEAL

RUBBER SEAL

RUBBER SEAL

QTY.

REMARKS

2

4

6

4

RUBBER SEAL

RUBBER SEAL

4

1

RUBBER SEAL ............................................... 2 ......... S/N3691259 TO 3701673

RUBBER SEAL ............................................... 2 ......... S/N3701674 AND ABOVE

RUBBER SEAL

RUBBER SEAL

RUBBER SEAL

2

4

4


OIL PIPING ASSY.

DCA-300SSK OIL PIPING ASSY.


OIL PIPING ASSY.

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

0602023040

C2324400004

0017110025

0017106025

7522054204

0131506000

0120006005

3972027104

0191600900

0605515074

0193301200

0605515004

PART NAME

PUMP

BRACKET, PUMP

HEX., HEAD BOLT

HEX., HEAD BOLT

BUSHING

NIPPLE

VALVE

HOSE JOINT

HOSE

HOSE BAND

HOSE

HOSE BAND

DCA-300SSK OIL PIPING ASSY.

1

1

1

2

1

2

1

1

QTY.

REMARKS

2

5

1

1


NAMEPLATE AND DECALS

DCA-300SSK NAMEPLATE AND DECALS



19

19

20

20

21

22

12

13

14

15

8

9

10

11

3

6

7

4

5


NO.

PART NO.

1

2

1

1

2

0800655603

C155100503

C155200403

B155200103

C952210003

PART NAME

DECAL; HANDLING PROCED.; S2763A 1

DECAL; HANDLING PROCED.; C1510050 1

DECAL; HANDLING PROCED.; C1520040 1

DECAL; CAUTION; B15200010 2

DECAL; CAUTION; C92210000

QTY.

REMARKS

2

S/N3691259 TO 3696506

S/N3696507 TO 3701673

S/N3701674~

S/N3696507 TO 3701673

S/N3701674~

0800520100

0800520904

0800520814

0840624504

0840624704

0840624604

0840624804

B9531100604

C0551000903

C2551000004

C2561101903

C9502400004

0600500091

CONTROL BOX GROUP

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

PLATE; AMMETER CHNG.-OVR SWITCH ..... 1 ......... N-2438

PLATE; VOLTMETER CHNG.-OVR SWITCH .. 1 ......... N-2439

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

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

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

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

DECAL; WARNING .......................................... 1 ......... B93110060

DECAL; SETTING FOR OUTPUT VOLTAGE. . 1 ......... C0510009

DECAL; SAFETY INSTRUCTIONS ................. 1 ......... C25100000

DECAL; WHISPERWATT 300 .......................... 1 ......... C26110190

DECAL; HIGH IDLE SPEED, C90240000 ........ 1 ......... S/N3701674~

DECAL; ENGINE CONTROLLER .................... 1 ......... S/N3696507~

23

23

5-8

0840625004

C155200013

0840625104

C9501400304

C0551000504

C0551000704

C0551000804

0840647804

5-1 0840614104

5-2 0840619904

5-3 B4551000103

5-4 B9511100304

5-5 B9511100404

5-6 B9531100504

5-7 C0551000404

C1551000404

ENGINE OPERATING PANEL GROUP

DECAL; PREHEAT LAMP, S-3036 .................. 1 ......... S/N3691259 TO 3701673

DECAL; OPERATING PANEL, C15200001 ...... 1 ......... S/N3701674~

DECAL; STARTER SWITCH, S-3037 .............. 1 ......... S/N3691259 TO 3696506

DECAL; PREHEAT BUTTON, C90140030 ....... 1 ......... S/N3696507 TO 3701673

DECAL; BATTERY SWITCH ........................... 1 ......... C05100050

DECAL; LOW-HIGH, C05100070 ..................... 1 ......... S/N3691259 TO 3701673

DECAL; STOP BUTTON, C05100080 .............. 1 ......... S/N3691259 TO 3696506

DECAL; EMERGENCY STOP, S4100 ............. 1 ......... S/N3696507 TO 3701673

DECAL; GROUND

DECAL; DANGER

1

1

S-2635

S-2731

DECAL; RECEPT. & CIRCT. BREAKER

DECAL; WARNING

DECAL; WARNING

DECAL; WARNING

DECAL; 3-PHASE OUTPUT TERMINAL

DECAL; 240/139 VOLT

1

1

1

1

1

2

B45100010

B91110030

B91110040

B93110050

C05100040

C15100040





DCA-300SSK NAME PLATE AND DECALS

35

36

37

38

32

33

34

24

25

26

26

27

28

29

30

31

31


NO.

PART NO.

16

17

18

6360610304

B9504000404

B9504100104

PART NAME QTY.

REMARKS

ENGINE & RADIATOR GROUP

DECAL; WATER ......................................................... 1............ S-1880

DECAL; WARNING .................................................... 2............ B90400040

DECAL; WARNING .................................................... 1............ B90410010

0840614104

0840619904

B4551000103

C1551000803

B9511100304

B9511100404

B9531100504

C0551000404

C1551000404

9039209064

OUTPUT TERMINAL GROUP

DECAL; GROUND ..................................................... 1............ S-2635

DECAL; DANGER ...................................................... 1............ S-2731

DECAL; RECEPT. & CIRCT. BREAKER,B45100010 . 1............ S/N3691259 TO 3706720

DECAL; RECEPT. & CIRCT. BREAKER,C15100080 . 1............ S/N3706721AND ABOVE

DECAL; WARNING .................................................... 1............ B91110030

DECAL; WARNING .................................................... 1............ B91110040

DECAL; WARNING .................................................... 1............ B93110050

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

DECAL; 240/139 VOLT, C15100040 ........................... 2............ UP TO S/N3696506

DECAL; START CONTACT, S4468 ............................ 1............ S/N3696507 AND ABOVE

0800689404

0800689504

C9505300004

B9504200004

1320620904

6360620004

B9504500004

BATTERY GROUP

DECAL; + .................................................................. 1............ S-2090

DECAL; - ................................................................... 1............ S-2091

DECAL; CAUTION ..................................................... 1............ C90530000

MUFFLER GROUP

DECAL; WARNING .................................................... 1............ B90420000

FUEL TANK GROUP

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

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

DECAL; WARNING .................................................... 1............ B90450000







NO.

PART NO.

48

49

50

50

46

46

47

47

51

42

43

44

45

39

40

41

1320610603

1320621504

0840625902

B9504000304

B9531100604

C2561101003

C2561101603

C2561101303

C2561102003

C2561101404

C2561102103

C2561101204

C2561101803

C2561101503

C2561102203

C2561101703

PART NAME QTY.

REMARKS

ENCLOSURE GROUP

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

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

DECAL; MQ ............................................................... 1............ S-3057

DECAL; CAUTION ..................................................... 1............ B90400030

DECAL; WARNING .................................................... 1............ B93110060

STRIPE

STRIPE

1

1

STRIPE ..................................................................... 1............ TO S/N 3708296

STRIPE ..................................................................... 1............ S/N 3708297 AND ABOVE

STRIPE ..................................................................... 1............ TO S/N 3708296

STRIPE ..................................................................... 2............ S/N 3708297AND ABOVE

STRIPE

STRIPE

2

1

STRIPE ..................................................................... 1............ TO S/N 3708296

STRIPE ..................................................................... 1............ S/N 3708297 AND ABOVE

STRIPE ..................................................................... 1............ TO S/N 3708296


Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

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

2.

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

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

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

b. The list must be typed or computer generated.

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

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

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

3.

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

4.

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

Multiquip’s designated receiving point.

5.

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

6.

The following items are not returnable: a. Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.) b. Any parts with a limited shelf life

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

c. Any line item with an extended dealer net price of less than $5.00.

d. Special order items.

e. Electrical components.

f.

Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7.

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

8.

Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

9.

Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge.

10. In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

11. Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price.

Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original

Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.


NOTE PAGE


OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING


800-427-1244 or 310-537-3700

FAX: 800-672-7877 or 310-637-3284


800-421-1244

FAX: 310- 537-4259


800-478-1244

FAX: 310- 631-5032


888-661-4279, or 310-661-4279

FAX: 310- 537-1173

Manufactured for Multiquip Inc.

by

DENYO CO., LTD, JAPAN MULTIQUIP INC.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-537-3927

E-MAIL: [email protected]

WWW: multiquip.com

Atlanta • Boise • Dallas • Houston • Newark

Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX

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