■ High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns.

■ 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.

■ 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.

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

CAUTION:

Always refuel in a well-ventilated area, away from sparks and open flames.

■ 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.

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

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

■ Always use extreme CAUTION when working with flammable liquids.

When refueling, stop the engine and allow it to cool. DO NOT smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

■ 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.

■ Topping-off to filler port is dangerous, as it tends to spill fuel.

PAGE 6 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

CAUTION

RULES FOR SAFE OPERATION

CAUTION

DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

NEVER touch output terminals during operation. This is extremely dangerous.

Always stop the machine when contact with the output terminals.

CAUTION

Radiator

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

■

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.

CAUTION

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

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

■

Never use damaged or worn cables when connecting power tools or 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 and electrical shock.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 7

B a t t e r y

CAUTION:

Never over fill the battery with water above the upper limit.

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. Use the following guidelines when handling the battery:

RULES FOR SAFE OPERATION

NEVER Run engine without air filter. Severe engine damage may occur.

Always service air cleaner frequently to prevent carburetor malfunction.

Always disconnect the battery before performing service on the generator.

Always be sure the operator is familiar with proper safety precautions and operations techniques before using generator.

Always store equipment properly when not in use.

Equipment should be stored in a clean, dry location out of the reach of children.

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

DO NOT allow unauthorized people to operate this equipment.

Always read, understand, and follow procedures in

Operator’s Manual before attempting to operate equipment.

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

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

2. DO NOT expose the battery to 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.

3. Always keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

Loading and Unloading (Crane)

Before lifting, make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.

Always drain fuel prior to lifting.

Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator.

NEVER lift the machine while the engine is running.

Use adequate lifting cable (wire or rope) of sufficient strength.

When lifting the generator, always use the balanced center-point suspension hook and lift straight upwards.

NEVER allow any person or animal to stand underneath the machine while lifting.

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

PAGE 8 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

Transporting

■ Always shutdown engine before transporting.

■ Tighten fuel tank cap securely.

■ Drain fuel when transporting generator over long distances or bad roads.

■ Always tie-down the generator during transportation by securing the generator.

■ If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See page 10 for basic towing procedures.

Emergencies

■ Always know the location of the nearest fire extinguisher and first aid kit. Know the location of the nearest telephone. Also know the phone numbers of the nearest ambulance, doctor and fire department.

RULES FOR SAFE OPERATION

Maintenance Safety

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

■ 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.

■ Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

■ DO NOT use plastic containers to dispose of hazardous waste.

■ DO NOT pour waste, oil, coolant or fuel directly onto the ground, down a drain or into any water source

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 9

Towing Safety Precautions

CAUTION :

Check with your county or state safety towing regulations department before towing your generator.

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer

(Figure 1) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

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

■ 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. Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "Safety

Chain".

DCA-220SSK — TOWING

■ ALWAYS attach trailer's safety chain to bumper of towing vehicle.

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

■ Remember the maximum speed unless otherwise posted for highway towing is 45 MPH. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

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

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

■ Use the trailer's hand winch to adjust the height of the trailer, then insert locking pin to lock wheel stand in place, while parked.

■ Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■ Avoid sharp turns to prevent rolling.

■ Remove wheel stand when transporting.

■ DO NOT transport generator with fuel in tank.

Figure 1. Generator with Trailer

PAGE 10 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — TRAILER-SAFETY GUIDELINES

CAUTION:

ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intendedto provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in thie section:

Brakes

Tires

Lug Nut Torquing

Suspension

Electrical

Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

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 - This measurment is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This 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 - Thr 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 4 and Figure 5 or 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 (see Table 3). Please not 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. See Figure 19 for proper wiring connections.

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

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 11

DCA-220SSK —TRAILER-SPECIFICATIONS

M O D E L

T R L R 7 0 W

T R L R 7 0 X

T R L R 7 0 X F

T R L R 1 0 0 X F

T R L R 8 5 / 1 2 5

T R L R 1 5 0 X F

T R L R 2 2 0 X F

T R L R 3 0 0 X F

T R L R 4 0 0 X F

T R L R 6 0 0 X F

T R L R 8 0 0 S X

T R L R 1 0 1 5

T R L R 1 0 X

T R L R 1 0 X F

T R L R 2 2 5 W

B L W 4 0 0

T R L R 1 5 X F

T R L R 5 0 X

T R L R 5 0 X F

T R L R 2 5 S B T

T L G 1 2 , D C A 1 5 ,

T L W 3 0 0

T L G 1 2 , D C A 1 5 ,

T L W 3 0 0

T L G 1 2 , D C A 1 5 ,

T L W 3 0 0

D C A 1 0

B L W 4 0 0

D C A 1 5

D C A 2 5

D C A 4 5 , 6 0 , 7 0

D C A 1 0 0 , 1 2 5

D C A 8 5 ,

1 2 5

1 0 0 ,

D C A 1 5 0 , 1 8 0

D C A 2 2 0

D C A 3 0 0

D C A 4 0 0

D C A 6 0 0 , 8 0 0

A P P L I C A T I O N F U E L

C E L L

N O

T a b l e 1 .

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

B R A K E

S Y S T E M

N O

G V W R

1 9 0 0 L B S

N O 1 9 0 0 L B S

F R A M E

L E N G T H

9 6 "

F R A M E

W I D T H

5 0 "

A L

G A

1 5 0 G A L

1 4 5 G A L

2 5 0 G A L

3 5 0 G A L

L E C

T R I C

H Y D R A U L I C S U R G E

H Y D R A

A U

U L I C

L E C

I C

U R G E

T R I C

1 9 0 0 L B S

2 2 0 0 L B S

2 7 0 0 L B S

W / M A

W /

T 1 5 4 "

1 2 4 "

( 7 8 "

5 5 "

T A L L )

5 5 "

1 2 4 " 5 5 "

2 7 0 0 L B S

2 9 9 0 L B S

7 0 0 0 L B S

0 0

1 1

0 L

0 0

1 6

1 4 0

1 8 0

B S

L B

0 L

B S

0 0 L B

1 9 0 "

1 8 6 "

2 0 4 "

2 2 2 "

3 8 4 "

7 6 "

7 7 "

8 4 "

8 3 "

5 5 "

6 6 "

7 7 "

6 6 "

J A C K

S T A N D

2 0 0 0 L B .

L A T P A D

2 0 0 0 L B .

L A T P A D

5 0 0 0

L A T

L B .

P A D

5 0 0 0 L B .

F L A T P A D

5 0 0 0

L A T

L B .

P A D

5 0 0 0 L B .

F L A T P A D

5 0 0 0

L A T

L B .

P A D

5 0 0 0

L A T

L B .

P A D

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

F U L L

8 0 0 L B .

T I L T W H E E L

2 0 0 0 L B .

L A T P A D

2 0 0 0 L B .

L A T P A D

2 0 0 0 L B .

L A T P A D

PAGE 12 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK —TRAILER-SPECIFICATIONS

M O D E L

T R L R 1 0 1 5 W

T R L R 1 0 X

T R L R 1 0 X F

T R L R 2 2 5 W

B L W 4 0 0

T R L R 1 5 X F

C O U P L E R

2 " B A L L C L A S S

2 A D J U S T A B L E

2 " B A L L

2 A D J

C L

U S T A

A S S

B L E

2 " B A L L

2 A D J

C L

U S T A

A S S

B L E

2 " B A L L

2 A D J

C L

U S T A

A S S

B L E

2 " B A L L

2 A D J

C L A S S

U S T A B L E

2 " B A L L C L A S S

T I R E S

1 7 5 1 3 C

1 7 5 1 3 B

1 7 5 1 3 C

T a b l e 1 .

S p e c i f i c a t i o n s ( C o n ' t )

B 7 8 1 3 L R C

T R L R 5 0 X

T R L R 5 0 X F

2 " B A L L C L A S S

2 " B A L L C L A S S B 7 8 1 3 L R C

T R

L R

0 X

T R L R 1 0 0 X F

T R L R 8 5 / 1 2 5

T R L R 1 5 0 X F

2 "

3 "

B A L L C L A S S

A D J U S T A B L E

2 "

3 "

B A L L C L A S S

A D J U S T A B L E

2 "

3 "

B A L L C L A S S

A D J U S T A B L E

A D J U S T A B L E 2 5 / 6

O P T 3 " E Y E

A D J U S T A B L E 2 5 / 6

O P T 3 " E Y E

3 " B A L L E Y E

R L

R -

2 2

3 0

4 0

6 0

8 0

0 X

0 A

D J U S

T A

W H

Y E

B L

E E

2 0 5 1 4 C

B I A S ( 4 )

2 0 5 1 4 C

B I A S ( 4 )

2 0 5 1 4 C

B I A S ( 4 )

2 0 5 1 5 C

B I A S ( 4 )

S T 2 2 5 / 7 5 R 1 5 D

R A D I A L ( 4 )

7 5 0 1 6

B I A S

( 4 )

S T 2 3 5 / 8 5 R 1 6 E

R A D I A L ( 4 )

S T 2 3 5 / 8 5 R 1 6 E

R A D I A L ( 6 )

S T 2 3 5 / 8 5 R 1 6 E

R A D I A L ( 6 )

S T 2 1 5 / 7 5 R 1 7 .

5 H

R A D I A L ( 8 )

S T 2 1 5 / 7 5 R 1 7 .

5 H

R A D I A L ( 8 )

W H E E L S

1 3 " X 4 .

5 0 "

1 3 " X 4 .

5 "

1 3 " X 4 .

5 "

1 3 X 4 .

5 "

1 3 X 4 .

5 "

A X L E

2 2 0 0 # 2 X 2

H U B S S U S P E N S I O N

5 L U G 3 L E A F

E L E C T R I C A L

4 W

R E

O L

L O O M W /

E F L A T

4 P O L E F L A T

2 2 0 0 # 2 X 2 5 L U G

1 3 " X 4 .

5 0 " 3 5 0 0 # 2 1 / 2 " 5 L U G

1 3 " X 4 .

5 0 "

1 3 " X 4 .

5 0 "

1 4 " X 5 "

1 4 " X 5 .

5 "

1 4 " x 6 "

1 6 " X 7 "

3 5 0 0 l b s .

2 3 / 8 "

3 5 0 0 l b s .

2 3 / 8 "

3 5 0 0 l b s .

3 "

3 5 0 0 l b s

3 "

3 5 0 0 l b s .

3 "

3 5 0 0 l b s

3 "

( 2 ) 6 0 0 0 l b s

5 L U G

6 L U G

( 2 ) 6 0 0 0 l b s 8 L U G

( 2 ) 7 0 0 0 l b s 8 L U G

( 2 ) 6 0 0 0 l b s 8 L U G

( 3 ) 7 0 0 0 l b s .

8 L U G

( 3 ) 1 0 0 0 0 l b s 8 L U G

3 L E A F

Q F L E X

3 L E A F

4 L E A F

5 L E A F

7 L E A F

Q F L E X

7 L E A F

A I R R I D E

4 P O L E F L A T

4 P O L E R U B B E R

F L A T

4 P O L E R U B B E R

F L A T

4 P O L E R U

F L A T

B B E R

4 P O L E R U

F L A T

B B E R

4 P O L E R U

F L A T

B B E R

4 P O L E R U

F L A T

B B E R

4 W I R E L O O M

6 W I R E L O O M

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 13

DCA-220SSK — TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the 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.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet.

Listed below are some of the advantages that electric brakes have over hydraulic brakes:

Brake system can be manually adjusted to provide the corrected braking capability for varying road and load conditions

Brake system can be modulated to provide more or less braking force, thus easing the brake load on the towing vehicle

Brake system has very little lag time between the time the vehicle’s brakes are actuated and the trailer’s brakes are actuated

Brake system can provide an independent emergency brake system

Remember in order to properly synchronize the tow vehicle’s braking to the trailer’s braking, can only be accomplished by road testing. Brake lockup, grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h.

decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required.

Electric 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. 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 6 on the remaining brakes.

PAGE 14 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure3 below displays the major hydraulic/air/surge brake components that will requrie inspection and maintenance.

Please inspect these components as required using steps

1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 15

DCA-220SSK — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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

CAUTION:

DO NOT attemp to repair or modify a wheel. DO NOT install in inner tube to correct a leak through thE rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode

(break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

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

DO NOTbleed air from tires when they ar hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Suspension

The leaf suspension springs and associated components

(Figure 4) 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 3.

CAUTION:

Figure 4. Major Suspension Components

NOTE

ALWAYS wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — TRAILER SAFETY GUIDELINES

T a b l e 3 .

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

3 / 8 " U B O L T

7 / 1 6 " U B O L T

T o r q u e ( F t -.

L b s ).

M I N 3 0 M A X 3 5

M I N 4 5 M A X 6 0

1 / 2 " U B O L T

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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 attachement of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 5. DO

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

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

Check all wheel lug nuts periodically.

T a b l e 4 .

W h e e l S i z e

1 2 "

T ri e T

F ri

F s t

T L

P a s

B S s

2 0 2 5 o r q u e R e q u ri e m e n t s

S e c o n d

F T

P a s s

L B S

3 5 4 0

T h ri d

F T

P a s s

L B S

5 0 6 5

1 3 "

1 4 "

1 5 "

1 6 "

2 0 2 5

3 5 4 0

5 0 6 0

5 0 6 5

9 0 1 2 0

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

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

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 17

DCA-220SSK — TRAILER SAFETY GUIDELINES

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK —TRAILER-BRAKE TROUBLESHOOTING

T a b l e 5 .

E l e c t r i c B r a k e T r o u b l e s h o o it n g

S y m p t o m

N o B r a k e s o r I n t e r m i tt e n t B r a k e s

W e a k B r a k e s

O n e o r

S i

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

P o s s i b l e C a u s e

A n y o p e n c ri c u ti s o r b r o k e n w ri e s ?

A n y s h o r t c ri c u ti s ?

F a u tl y c o n t r o ll e r ?

A n y l o o s e c o n n e c it o n s ?

G r o u n d w ri e s e c u r e ?

G r e a s e o r o li o n m a g n e t s o r il n i n g s ?

C o n n e c it o n s c o r r o d e d ?

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

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 ?

B r a k e s s y n c h r o n i z e d ?

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 ir 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 e a ir n g s o f t h e w h e e l a d j u s t e d ?

S o l u it o n

F i n d a n d c o r r e c .t

T e s t a n d c o r r e c .t

F i n d a n d r e p a i .r

F i n d a n d s e c u r e .

C l e a n o r r e p l a c e .

C l e a n a o f n d c c o r r o o r s i r e c t o n .

c a u s e

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

C o r r e c .t

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 ir c a t e .

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

A d j u s .t

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 19

DCA-220SSK —TRAILER-BRAKE TROUBLESHOOTING

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 a b l e 6 .

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

N o B r a k e s

W e a k B r a k e s

O n e o r

S i

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

P o s s i b l e C a u s e

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 ?

T r a li e r o v e lr 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 ir 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 w c r o k n n e s s g p o s i c it o o r r e n ?

c t o r i n

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

S o l u t i o n

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 .

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 ir 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 il e w n i s n g h s .

o e s a n d

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

r t s

PAGE 20 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK —OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-220SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 21

DCA-220SSK —OPERATION AND SAFETY DECALS

PAGE 22 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK —OPERATION AND SAFETY DECALS

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 23

DCA-220SSK —OPERATION AND SAFETY DECALS

PAGE 24 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK SPECIFICATIONS

M o d e l

T y p e

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

P h a s e

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

P ir m e O u t p u t

V o tl a g e

F r e q u e n c y

S p e e d

P o w e r F a c t o r

A u x .

A C P o w e r

V o tl a g e

O u t p u t

M o d e l

T y p e

N o .

o f C y il 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 it n g

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

L u b e O li C a p a c ti y

F u e l C o n s u m p it o n

B a tt e r y

F u e l

T a b l e 7 .

S p e c i if c a it o n s

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

D C A 2 2 0 S S K

R e v o l v i n g if e l d , s e fl v e n t li a t e d , o p e n p r o t e c t e d t y p e s y n c h r o n o u s g e n e r a t o r

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

2 4 2 K V A ( 1 9 3 .

6 K W )

2 2 0 K V A ( 1 7 6 K W )

2 4 0 V o r 4 8 0 V

6 0 H z

1 8 0 0 r p m

0 .

S i n g l e P h a s e , 6 0 H z

1 2 0 V

4 .

8 K W ( 2 .

4 K W x 2 )

E n g i n e S p e c i if c a it o n s

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

4 C y c l e , w a t e r c o o l e d , d ri e c t i n j e c it o n , t u r b o c h a r g e d

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 )

2 7 3 H P / 1 8 0 0 r p m

6 7 1 c u .

i n .

( 1 1 0 0 0 c c )

E l e c t ir c

1 1 .

1 g a .l

( 4 2 l ti e r s )

1 0 .

4 g a .l

( 4 0 l ti e r s )

1 2 .

3 g a (l 4 6 .

6 L /) h r a t f u ll l o a d 9 .

4 g a (l 3 5 .

6 L /) h r a t 3 / 4 l o a d

6 .

5 g a (l 2 4 .

6 L /) h r a t 1 / 2 l o a d 4 .

0 g a (l 1 5 .

1 L /) h r a t 1 / 4 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

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 25

DCA-220SSK — GENERAL INFORMATION

DCA-220SSK FAMILIARIZATION

Generator

The MQ Power Model DCA-220SSK is a 176 kW generator that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Control Panel

The “Engine Control Panel” is provided with the following: z Tachometer z Water Temperature Gauge z Oil Pressure Gauge z Charging Ammeter Gauge z Engine Warning Lamp Module z Engine Speed Switch z Pre-Heat Button z Pre-Heat Lamp z Emergency Stop Button z Battery Switch

Control Box

The “Control Box” is provided with the following: z Main Circuit Breaker 600 amps z Over-Current Relay z High Idle Adjust Trimmer

Microprocessor Controlled Alarm System

The DCA-220SSK generator is equipped with various alarms and LED status indicators. These alarms and status indicators are provided to add safety to the generator when operating under normal conditions. The DCA-220SSK generator is designed to shutdown in the event of low oil, high coolant temperature, low battery and other operation conditions that may cause severe damage to the generator.

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 MPEC Module z Pilot Lamp

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

Open Delta Excitation System

The DCA-220SSK generator is equipped with the state of the art "Open-Delta" excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four 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.

z Three 240/139V output receptacles, 50 amp z Two 120V input receptacles, 20 amp z 3 Load Circuit Breakers 265V @65 amps z 2 Load GFCI Circuit Breakers [email protected] 20amps

PAGE 26 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERAL INFORMATION

Engine

The DCA-220SSK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D125E-2 diesel engine.

This engine is designed to meet every performance requirement for the generator. Reference Table 7, page 26 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-220SSK generator are addressed on the following pages.

Electronic Governor System

The electronic governor system replaces the standard mechanical governor system. The frequency regulation improves from ±3.0% regulation with the mechanical governor to ±0.25% regulation with the electronic governor system.

CAUTION :

ALWAYS unplug the jacket water heater before servicing.

Battery Charger

The battery charger will operate in a ‘BOOST’ mode until the battery’s current acceptance falls to 70% of the charger’s rating. The charger will then go into a ‘FLOAT’ mode, where it discharges a lower voltage until an AC failure, or the battery is discharged.

Jacket Water Heater

The jacket water heater is a 1500-watt heater designed to keep the coolant warm in the engine block for fast starts and load acceptance. The heater is thermostatically controlled and once an acceptable engine temperature is achieved it will cycle on and off, operating only about 1/3 of the time, which makes it more efficient than the direct block type heater. It is designed to keep the engine coolant between 100 and 120 degrees fahrenheit.

Under normal conditions, 20 to 15 minutes is required to raise the engine temperature of a cold engine to 100 degrees fahrenheit.

NOTE:

The jacket water heater can be serviced if not functioning propertly.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 27

DCA-220SSK — WATER SEPARATOR FILTER

Water Separator Filter

The DCA-220SSK generator is equipped with a “Water Fuel

Separator. This unit is designed to prevent dirt, rust, algae, varnishes and water from entering the fuel system.

CAUTION:

DO NOT turn the control valve while the generator is in operation. This may stop fuel flow to the generator if both filters are set to the OFF position.

This water separator system is designed around two filters connected in parallel (Figure 6). These two filters can be configured in a variety of ways to filter water from the fuel system.

For best results it is best to have both filters active (ON) at the same time or use only one filter, and use the other filter as a reserve, that way you can use the filters alternately every time the filter element is replaced.

Figure 6. Water Separator Filter

Collection Bowl Water Drainage

Inspect or drain the water in the collection bowl daily. The collection bowl must be drained before contaminants reach the bottom of the turbine.

To drain the collection bowl perform the following:

Open the self-venting drain to evacuate contaminants with a suitable collection container in place.

Prime the unit by removing the filter lid and filling with clean fuel.

Replace the filter lid and snugly tighten the T-handle by hand only.

PAGE 28 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — MAJOR COMPONENTS

Figure 7. Major Components

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 29

DCA-220SSK — DIMENSIONS (TOP AND SIDE)

Figure 8a. Dimensions

PAGE 30 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — DIMENSIONS (FRONT AND REAR)

Figure 8b. Dimensions

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 31

DCA-220SSK — CONTROL PANEL

Figure 9. Control Panel

PAGE 32 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — CONTROL PANEL

The definitions below describe the controls and functions of the DCA-220SSK " Control Panel "(Figure 9).

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

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

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.

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

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.

Pilot Lamp – Indicates that the generator is working properly.

Main Circuit Breaker – This three-pole, 600 amp main breaker is provided to protect the UNV voltage output terminals from overload.

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

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.

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

11. MPEC –

M i c r o p r o c e s s o r

Engine Control

Module – (MPEC) has a vertical row of status LED's (Figure

10), that when lit, indicate that an engine malfunction (fault),

Figure 10. MPEC Module

has been detected.

When a fault has been detected the MPEC will evaluate the fault and all major faults will shutdown the generator.

During cranking cycle , The MPEC will attempt to crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third attempt, the engine will be shut-down by the MPEC's " Over Crank

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

Also the MPEC will shut-down 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 MPEC module.

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.

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.

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.

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. It is pre-set at 3 cycles with a 10 second duration. This is considered a major fault.

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

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

12. Kilowatt Meter - Indicats the output power of the generator.

13. High Idle Adjust Trimmer - Used to adjust the engine speed.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 33

DCA-220SSK — ENGINE OPERATING PANEL

NO. NAME

1 THROTTLE HANDLE

TACHOMETER

ENGINE WARNING DISPLAY LED

OIL PRESSURE GAUGE

WATER TEMPURATURE GAUGE

CHARGING AMMETER

FUEL LEVEL GAUGE

PREHEAT LAMP

PREHEAT BUTTON

EMERGENCY STOP BUTTON

BATTERY SWITCH

Figure 11. Engine Operating Panel

PAGE 34 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-220SSK " Engine Operating Panel "(Figure 11).

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

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.

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

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.

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

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.

Fuel Gauge - Indicates amount of diesel fuel available.

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

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 shut-down device will stop the engine automatically.

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 start-up the lamp will go OFF. If this lamp is ever lit (ON) during normal operation of the generator, the emergency shut-down device will stop the engine automatically.

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.

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.

9. Pre-Heat Button – Press hold this button until the pre-heat 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. 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.

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.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 35

DCA-220SSK — OUTPUT TERMINAL PANEL

Figure 12. Output Terminal Panel

PAGE 36 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — OUTPUT TERMINAL VOLTAGE SELECTION

Figure 13. Output Terminal Voltage Selection

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 37

DCA-220SSK — INSTALLATION

Outdoor Installation

Install the generator in a location where it will not be exposed to rain or sunshine. Make sure the generator is on secure level ground so it cannot slide or shift around. Also install the generator so the exhaust will not be discharged in the direction of nearby homes.

CAUTION :

An electric shock may happen when vibrators are used. Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock.

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 the engine parts and alternator.

CAUTION :

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

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

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

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

) or larger.

b. Aluminum - 8 AWG (8.4 mm

) or larger.

2. When grounding the generator (Figure 14) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

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

NOTE

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

PAGE 38 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — INSTALLATION

Figure 14. Typical Generator Grounding Application

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 39

DCA-220SSK — PRE-SETUP

General Inspection Prior to Operation

The DCA-220SSK generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the Cable Selection Guide (Table 8) as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 600 amp, main circuit breaker is provided to protect the UNV 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 load side of the generator from overload. Make sure to switch ALL circuit breakers to the "OFF" position prior to starting the engine.

NOTE

ALWAYS consult with a licensed electrician for correct extension cord wire size.

A u r r m p e n e r t i n e s

2 .

T a b l e 8 .

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

L o a d I n W a tt s

A t

V o tl

1 2 s

3 0 0

V t o

6 tl

2 s

4 0

0 0

# 1 0 W ri e

1 0 0 0 f .t

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

# 1 2 W ri e

6 0 0 f .t

# 1 4 W ri e

3 7 5 f .t

# 1 6 W ri e

2 5 0 f .t

7 .

6 0 0

9 0 0

1 2 0 0

1 8 0 0

5 0 0 f .t

3 5 0 f .t

3 0 0 f .t

2 0 0 f .t

1 2 5 f .t

1 0 0 f .t

0 f f

2 0 2 4 0 0 4 8 0 0 1 2 5 f .t

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 rf o m l o w v o tl a g e .

1 5 0 f .t

1 0 0 f .t

7 5 f .t

1 0 0 f .t

6 5 f .t

5 0 f .t

PAGE 40 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — PRE-SETUP

Lubrication Oil

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

With the dipstick inserted all the way, but without being screw into the filler hole, verify the oil level is maintained between the two notches (Figure 15) on the dipstick. See Table 9 for proper selection of engine oil.

Fuel

Fill the fuel tank with clean and fresh diesel fuel. DO NOT fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 25,

Specification Table 7.

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.

CAUTION:

Never fill the fuel tank while the engine is running or in the dark. Diesel spillage on a hot engine can cause a fire or explosion.

If diesel spillage occurs, wipe up the spilled diesel completely to prevent fire hazards.

Figure 15. Engine Oil Dipstick

Coolant

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.

When checking the engine oil, be sure to check if the oil is clean and viscous. 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.

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

T a b l e 9 .

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

1 0 4 °

( 4 0 °

~ -

3 °

° C

)

5 °

3 °

5 °

C )

B e l o w 5 ° C -( 1 5 )°

S A E 3 0

S A E 2 0 o r S A E 1 0 W 3 0

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

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 41

DCA-220SSK — PRE-SETUP

CAUTION :

When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 10 for engine, radiator, and reserve tank coolant capacities. Make sure the coolant level in the reserve 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 battery 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.

T a b l e 1 0 .

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

The fan belt tension is proper if the fan belt bends 7 to 10 mm (Figure 16) when depressed with the thumb as shown below.

E n g i n e a n d R a d i a t o r 1 1 .

1 G a .l

( 4 2 .

0 L ti e r s )

R e s e r v e T a n k 2 Q u a tr s ( 1 .

9 L ti e r s )

Operation in Freezing Weather

When operating in freezing weather, be certain the proper

T a lb e 1 1 .

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

Figure 16. Fan Belt Tension

CAUTION :

F r e e iz n g P o i n t B o ili n g P o i n t

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

A n t

-i F l r

% z e

4 0

5 0

° C

2 4

3 7

NOTE

° F

1 2

3 4

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

° C

1 0 6

1 0 8

° F

2 2 2

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 is not properly maintained. Add only distilled water when replenishment is necessary.

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.

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 a thin film of grease will help to inhibit corrosion.

PAGE 42 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — PRE-SETUP

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 17) 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 :

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

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 17. Battery Connections

CAUTION :

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.

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery terminals when the Off/Manual/Auto switch is in either the manual or auto position (ON). ALWAYS make sure that the Off/

Manual/Auto switch is in the OFF position when connecting the battery..

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

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 43

DCA-220SSK — 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.

CAUTION:

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

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

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 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.

The power factor of this generator is 1.0. See Table 12.

below when connecting loads.

T a b l e 1 2 .

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

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

P o w e r F a c t o r

0 .

4 0 .

7 5 l

E l m c p t s ir c 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 q e c u i p rt o m n e i c n t d e iv c e s , c o m m u n i c a it o n

1 .

0 .

4 0 .

1 .

0 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.

CAUTION:

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

(transfer) switch. Serious injury or death may result without this transfer switch.

Three Phase Load

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

N O T E

If output (kVA) is not given on the equipment nameplate, approximate output may be determined by multiplying voltage by amperage by .

PAGE 44 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:

The engine's exhaust contains harmful emissions. ALWAYS ventilate the exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase with high grade motor oil. Use a high quality detergent oil classified CC or higher (See Table 9 on page 41).

3. Check the coolant level in the radiator and subtank.

Replenish with antifreeze as necessary. Always maintain the coolant level between the FULL and LOW markings on the coolant container. Be sure that the radiator cap is fastened securely.

4. Check the fuel level on the fuel gauge. If fuel is low, fill the fuel tank with clean fresh unleaded automotive diesel.

If diesel spillage occurs, completely wipe up the spilled fuel immediately.

Before Starting

Generator and Control Panel

CAUTION:

Jacket Water Heater and Internal Battery Charger 120

VAC Output Receptacles

This generator is equipped with two 120 VAC, 20 amp output receptacles located on the output terminal panel, page 36,

Figure 12.

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 20). To apply commercial power to these receptacles, a power cord of adequate size will be required.

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.

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.

NEVER start the engine with the main, GFCI or load circuit breakers in the ON position.

CAUTION:

1. Be sure to disconnect the electrical load and switch the main, load and G.F.C.I. circuit breakers (Figure 18) to the “OFF” position prior to starting the engine.

ALWAYS have power applied to the generator's internal battery charger when connecting the generator to a isolation (transfer) switch. Remember before connecting this generator to any buildings electrical system, have a licensed electrician perform the installation of the transfer switch.

Figure 18. Main, GFCI and

Load Circuit Breakers

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 45

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)

Figure 19. 120 VAC Accessory Receptacle/Cable

2. Once it is determined if commercial power is required, connect the load to the UNV terminals as shown in

Figure 20. These terminals can be found on the output terminal panel, see page 36 Figure 12. To gain access to the output terminals lift the UNV cover. Make sure to tighten terminal nuts securely to prevent load wires from slipping out.

3. Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 21).

NEGA

TIVE

POSTIVE

BATTER

Y

Figure 21. Battery Connections

Figure 20. UNV Terminal Lugs (Load)

PAGE 46 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)

4. Close all engine enclosure doors (Figure 22).

7. Place the Off/Manual/Auto switch (Figure 26) in the

MANUAL position (down). Observe that the engine begins to crank.

Figure 26. Off/Manual/Auto Switch (Manual)

Figure 22. Engine Enclosure Doors

5. Set the battery ON/OFF switch (Figure 23) to the ON position.

8. After engine starts, verify that the "Engine Running" status LED (Figure 27) on the Microprocessor Engine

Control Module (MPEC) display is "ON" (lit).

Figure 23. Battery ON/OFF Switch

6. When starting the generator in COLD weather conditions, press and hold the engine preheat button (Figure 24) until the pre-heat lamp (Figure 25) is lit (ON).

Figure 27. MPEC Engine Running Status LED

Figure 24. Engine Pre-Heat Button

Figure 25. Engine Pre-Heat Lamp

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 47

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)

9. The generator's frequency meter (Figure 28) displays the 60 cycle output frequency in HERTZ.

12. The wattmeter (Figure 32) will indicate zero watts with no load applied. When a load is applied, this meter will indicate the output power of the generator with respect to the applied load.

Figure 28. Frequency Meter (Hz)

Figure 32. Kilowatt Meter

10. The generator's voltage meter (Figure 29) displays the

120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 30) to increase or decrease the desired voltage.

13. The engine oil pressure gauge (Figure 33) will indicate the oil pressure (kg/ cm 2 ) of the engine. Under normal operating conditions the oil pressure should be approximately 25 psi.

Figure 29. Voltage Meter (Volts)

Figure 33. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 34) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between

165 and 215 degrees fahrenheit (Green Zone).

Figure 30. Voltage Adjust Control Knob

WATER TEMP

11. The ammeter (Figure 31) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator’s alternator.

Figure 34. Coolant Temperature Gauge

15. Set the engine speed switch (Figure 35) to low to idle engine, set to high when a load is being applied.

Figure 35. Engine Speed Switch

Figure 31. Ammeter (No Load)

PAGE 48 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)

16. The tachometer (Figure 36) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed should be approximately

1800 RPM’s.

20. Observe the generator's ammeter (Figure 39) and verify that it reads the anticipated amount of current with respect to the load. Remember the ammeter will only display a current reading if the load is in use.

Figure 36. Engine Tachometer

17. If the engine speed is too high or low, use the high idle adjust trimmer (Figure 37) located in the control box to adjust the rated speed of the engine.

Figure 39. Ammeter (Load)

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

Figure 37. Engine Idle Adjust Trimmer

18. After the engine has been running for a few minutes, look at the status LED’S on the "MPEC" display (Figure

27) and check it for any abnormal conditions. If any abnormal conditions exist, shut down the engine and take corrective action to solve the problem.

19. If there are no abnormal problems shown on the “MPEC"

LED display, turn the MAIN, GFCI and LOAD circuit breakers to their ON position (Figure 38).

Figure 38. Main and GFCI Circuit Breakers

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 49

DCA-220SSK — GENERATOR START-UP PROCEDURE (AUTO)

CAUTION:

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

(transfer) switch. Serious injury or death may result without this transfer switch.

CAUTION:

When starting generator in Auto mode use the "Manual Startup" procedure except where noted (see below).

1. Perform steps 1 through 6 (Before Starting, page 35-

39) as outlined in the manual starting procedure.

2. Apply commercial power to the internal battery charger receptacle (to ensure good starting) via commercial power. An external power cord will be required.

3. Apply commercial power to the jacket water heater receptacle (not necessary for warm climates) via commercial power. An external power cord will be required.

4. Place the Off/Manual/Auto switch (Figure 40) in the

AUTO position (up).

Starting the generator in the "AUTO" mode is similar to starting the generator in the "MANUAL" mode, with a few exceptions.

CAUTION:

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 40. Off/Manual Auto Switch

(AUTO)

5. Continue to follow the steps outline in the manual startup procedure (start at step 9, page 38).

PAGE 50 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERATOR SHUT-DOWN PROCEDURE

Engine Shutdown

To shut-down the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers to the "OFF position".

2. Set the engine speed switch (Figure 41) to the idle (low) position.

Emergency Stop

1. To stop the engine in the event of an emergency, PUSH the emergency stop button ( Figure 44) inward. This button is located on the generator's engine operating panel, see page 26, Figure 5.

Figure 41. Engine Speed Switch

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

4. Place the Off/Manual/Auto Switch (Figure 42) in the "OFF/

RESET" position

Figure 44. Emergency Stop Button

CAUTION:

NEVER stop the engine suddenly except in an emergency. DO NOT use the emergency stop switch a as method of shutting down the engine. This switch is

ONLY to be used in the event of an emergency.

Figure 42. Off/Manual Auto Switch (OFF)

5. Verify that the "Engine Running" status LED (Figure 43) on the Microprocessor Engine Control Module (MPEC) display is "OFF" (not lit).

Figure 43. MPEC Engine Running

Status LED (OFF)

6. Remove the load from the UNV terminal strip (Figure 20).

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 51

DCA-220SSK — MAINTENANCE

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.

Engine Side, Fuel, Oil and Coolant (Refer to the Engine

Instruction Manual).

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy duty paper element with kerosene, or foam element with liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry. For heavy duty paper element, wipe excess kerosene with towel

Fuel Addition

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

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 15, page 41.

Generator Storage

For storage of the generator for over 30 days, the following is required: z Drain the fuel tank completely.

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

z Clean all external parts of the generator with a cloth.

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

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.

Water Separator Filter

Replace the water separator filter (Figure 45) every 500 hours if two filters are being used. If one filter is being used, replace every 250 hours.

The filters should also be replace if the vacuum gauge indicates between 6 to 10 inches of mercury (in Hg).

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.

Figure 45. Water Separator Gauge

PAGE 52 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — MAINTENANCE

To replace the water separator filter element perform the following:

1. Remove the lid from the filter housing. Remove the element by holding the module handle and slowly pulling upward with a twisting motion.

2. Replace the lid gasket with the one supplied with the new filter element. Apply a coating of clean fuel or motor oil to seal prior to reassembly. Insert the new filter element with a slow downward twisting motion.

3. Fill the unit with clean fuel, then set the lid back on top of the filter housing, and tighten snugly using the T-bar handle.

4. Start the engine and check for any leaks. If any leaks occur with the engine running, turn the engine off and fix the leak.

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 A ri C l e a n e r

C h e c k B a tt e r y A c i d L e v e l

C h e c k F a n B e tl C o n d i it o n

C h e c k f o r L e a k s

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

C h e c k W a t e r S e p a r a t o r

C h e c k B l o w b y O li M i s t T a n k

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

C l e a n A ri F i tl e r

D r a i n B o tt o m o f F u e l T a n k

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 *

R e p l a c e W a t e r S e p a r a t o r E l e m e n t * 3

C l e a n

P r o t e c it

R A d i a t o r o n 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

C h a n g e C o r r o s i o n R e s i s t o r

C h e c k a ll H o s e s a n d C l a m p s

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

D A I L Y s

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

( X )

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 .

R e f e r t o t h e ti e m " W a t e r S e p a r a t o r F i tl e r " .

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 53

DCA-220SSK — GENERATOR WIRING DIAGRAM

PAGE 54 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENGINE WIRING DIAGRAM

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 55

DCA-220SSK — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for diagnosis based on the Engine Troubleshooting

(Table 13). 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 tr e r d o e s n o t r u n .

T A B L E 1 3 .

E N G I N E 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 S O L U T I O N

N o f u e l ?

A ri i n t h e f u e l s y s t e m ?

W a t e r i n t h e f u e l s y s t e m ?

F u e l p i p e c l o g g e d ?

F u e l f tli e r c l o g g e d ?

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 rf 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 f tli e .r

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

U s e t h e s p e c ifi e d f u e l o r e n g i n e o .li

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 e t a k d a i n i u n e g t o n u t l o

o s e i n j e c it o n

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

F u e l c a m s h a tf w o r n ?

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

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

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

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

R i s g d e j e p h u

R e p l t

R e p a a t s h e e ri

n a c e .

C l e a n ri s p n u e c

i n j e c it o n o r o r n o z z l e .

r e p l a c e .

r e p l ifi e d a c e .

f u e .l

C o m p r e s is o n l e a k rf o m c y il n d e r ?

I m

K t i x a

W i s p r c a e y t ir o e tt e tr o p s n s r y e n g r e r ir n g is v e w ti d m v i s a c h a l a v e n d v a l v e c h a r fl u d i s c o n c m a it it m il n c l o n i n e r g ?

w e a r a g e d ?

fl u n c i n g ?

it o n n n e c t e d ?

o r n ?

n c e ?

i n g ?

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

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

C o rr 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

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

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

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

PAGE 56 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — TROUBLESHOOTING (ENGINE)

S Y M P T O M

T A B L E 1 3 .

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 )

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

F u e l f tli e r c l o g g e d o r d i tr 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 e t a k d a i n i u n e g t o n u t l o

o s e 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 ?

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

T i g h t e n n u .t

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

S O L U T I O N

E n g i n e r e v o l u it o n i s n o t s m o o t h .

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

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

I c n j l o e c g g it e o n 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 is v e e n g i n e o li ?

A d j u s .t

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

C l e a n .

R e p a i .r

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

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

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

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

a r k g r a y e x h a u s t

D e if ic e n t o u t p u .t

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

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

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

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

O v e lr o a d ?

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

F u e l f tli 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 ic e n t n o z z l e i n j e c it o n ?

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

E b n g e s i n e i

'e s iz n m o g ?

iv n g p a tr 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 ic e n t n o z z l e i n j e c it o n ?

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

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

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 ifi e d f u e .l

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

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 .

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 n o e p l a z z l e c e h o l h e d e a d

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-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 57

DCA-220SSK — TROUBLESHOOTING (GENERATOR/ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown fordiagnosis based on the Engine and Radiator Troubleshooting (Table14)and MPEC

Troubleshooting on next page(Table 15 ). If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

T A B L E 1 4 .

E N G I N E

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

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

S O L U T I O N r

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

f a li s t o s t a tr a n d s t a tr e r d o e s n o t

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

E n g i n e s t a tr s a n d r e m a i n s a t l o w s p e e d .

D e a d b a tt e r y ?

D e f e c it v e s t a tr e r s w ti c h ?

F u s e F 5 b u r n e d o u t ?

B r o k e n p r e h e a t c ri c u ti ?

N o f u e l ?

D e f e c it v e w i ir n g ?

C l o g g e d f u e l s rt a i n e r ?

C l o g g e d a ri lc e a n e r ?

D i s c o n n e c t e d w i ir n g ?

N o v o tl a g e p r e s e n t i n A C p o w e r s o u r c e ?

D e f e c it v e r o t o r ?

R e p l a c e b a tt e r .y

R e p l a c e s w ti c h .

R e p l a c e f u s e .

C h e c k p r e h e a t c ri c u i .t

A d d f u e .l

C h e c k w i ir n g .

C l e a n o r r e p l a c e .

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

R e p l a c e r e c t ifi e r ( R E 1 .)

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

E n p r e g i n s e e n t s n i p e e d

A C p ir s o e s w e r a s n d o u n o r c e .

v o tl a g e i s

E n v o g tl a i n e g e i s s p e t e d o o l o ir s e s w o r a n c d a n

A C n o t p b o e w u e r s e d .

E n d i s c g i n e h a r g s e p s e e d t o o ir s e s s o o n .

a n d b a tt e r y

D e f e c it v e v o tl m e t e r ?

D i s c o n n e c t e d w i ir n g ?

L a y e r s h o r -t c ri c u ti i n a r m a t u r e w i n d i n g ?

D e f e c it v e c ri c u ti b r e a k e r ( p r o t e c t o )r ?

L w i a y e r n d s h o r i n g ?

-t c ri c u i ,t b r o k e n w ri e s i n a r m a t u r e

D e f e c it v e e n g i n e r e g u l a t o r ?

D e f e c it v e w i ir n g ?

R e p l a c e v o tl m e t e .r

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

R e p l a c e a r m a t u r e .

R e p l a c e c ri c u ti b r e a k e r ( p r o t e c t o r .)

R e p a ri o r r e p l a c e a r m a t u r e .

R e p l a c e r e g u l a t o .r

R e p a ri o r r e p l a c e w i ir n g .

E n o v e g i n e lr o a d s e p e d .

e d ir s e s a n d e n g i n e s e e m s

D e f e c it v e a tl e r n a t o r ?

D a m a g e d a tl e r n a t o r b e a ir n g ?

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

R e p l a c e a tl e r n a t o r b e a ir n g s .

PAGE 58 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — TROUBLESHOOTING (MPEC)

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

L o w o li l e v e l ?

T A B L E 1 5 .

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

C a u s e S o l u it o n

F lli o li l e v e .l

L o i

L s o w n .

o w o n o

c li o o p r l a e s n t s u l e r e v e l il il g g h h t t i s

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 M P E C ?

W ri e s h o tr 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 b a tt e r y v o tl a g e ?

F a n b e tl t e n is o n i n c o rr 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 ?

H il g i g h h t i c s o o o l n .

a n t t e m p e tr u r e

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

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

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 .

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 ?

M P E C 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 rt o ll e r n e e d s t o b e a d j u s t e d ?

L o o n .

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

M P E C n e e d s t o b e c a il b r a t e d ?

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 i tr y ?

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 lli 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 ir .ll

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 lli f u e l l e v e .l

R e f e r t o d e a l e .r

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 rt o ll e .r

R e f e r t o d e a l 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 .

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 59

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column,

%, or

■, belong to the same assembly or kit.

, #, +,

Note: If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

PAGE 60 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — SUGGESTED SPARE PARTS

DCA-220SSK W/KOMATSU S6D125E-2

DIESEL ENGINE

Qty.

1 to 5 Units

P/N Description

5 ..................... 6125817032 ..................... AIR FILTER

10 ................... 6003118293 ..................... FUEL FILTER

10 ................... 6002111231 ..................... OIL FILTER

5 ..................... 6004111020 ..................... CARTRIDGE, CORROSION RESISTOR

1 ..................... 0601805950 ..................... MAIN CIRCUIT BREAKER

1 ..................... 0602115008 ..................... PILOT LAMP, ENGINE TROUBLE

2..................... 0601810204 ..................... BULB

2..................... 0412122262 ..................... ENGINE FAN BELT

2..................... 6008711170 ..................... OIL SWITCH

1 ..................... 6151619320 ..................... RADIATOR HOSE (UPPER)

1 ..................... 6151619330 ..................... RADIATOR HOSE (LOWER)

1 ..................... 0845500104 ..................... FUEL CAP

1 ..................... 0601820625 ..................... AUTOMATIC VOLTAGE REGULATOR

1 ..................... 0601807030 ..................... MAIN CIRCUIT BREAKER

1 ..................... 0601840073 ..................... VOLTAGE REGULATOR (RHEOSTAT)

1 ..................... 0601840121 ..................... KNOB, VOLTAGE REGULATOR

1 ..................... 0601810072 ..................... PILOT LAMP

2..................... 0601810261 ..................... BULB, PILOT LAMP

1 ..................... TR60110235100 ............... CAP, RADIATOR

1 ..................... 0602122200 ..................... UNIT, OIL PRESSURE

1 ..................... 0602123204 ..................... UNIT, WATER TEMPERATURE

1 ..................... 0602121052 ..................... CHARGING AMMETER

5 ..................... R30P................................ ELEMENT, WATER SEPARATOR ........... S/N3696501 TO S/N3698949

1 ..................... LGX500 ........................... FUEL CONDITIONER ............................. S/N3698950~

10 ................... R2010PMOR.................... ELEMENT, WATER SEPARATOR ........... S/N3698950~

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 61

GENERATOR ASSY.

DCA-220SSK — GENERATOR ASSY.

PAGE 62 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY.

REMARKS

1-1*

C1110100202

1-2* 0601842334

1-3* 0601823282

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

FIELD ASSY.

RESISTOR ........................................... 1 .......... SMRK 80W 100K OHM

RECTIFIER .......................................... 1 .......... RM507C24

1-4* 0018205020

0040005000

HEX. SOCKET HEAD CAP SCREW 2

LOCK WASHER 2

0041205000 PLAIN WASHER

1-5* 8171070002FAN

1-6* 8171611003

1-7* C1164200004

1-8* 8171015003

1-9* 0012116045

1-10* 0042616000

1-11* 0601000209

1-12* C1112500004

1-13* 0071906314

COUPLING DISK

WASHER, COUPLING HUB

BALANCING PLATE

HEX. HEAD BOLT

LOCK WASHER

BALANCING WEIGHT KIT

BEARING FLANGE

BEARING ............................................. 1 .......... 6314DDUC3

28171614003

3 0012112035

0042512000

0012112040

0042512000

C1130100103

7-1% 0226100420

7-2% 8171323004

7-3% 0223300120

7-4% 8171323103

7-5% 0221200300

7-6% 0010110035

7-7% 0041210000

7-8% C1132200003

7-9% 0226000510

7-10% 0225000470

7-11% 0017106016

COUPLING RING

HEX. HEAD BOLT

LOCK WASHER

HEX. HEAD BOLT

CLAMPER

RUBBER SEAL

HEX. HEAD BOLT

PLAIN WASHER

COVER

RUBBER SEAL

HEX. HEAD BOLT

LOCK WASHER 8

STRATOR ASSY. ................................. 1 .......... INCLUDES ITEMS W/%

RUBBER SEAL

CLAMPER

RUBBER SEAL

7-12% 0601850144

8 C1154000002

C1138000003

0012110065

0042610000

0041210000

11 0017112045

12C1154400004

C1154300004

0010106060

0040006000

0041206000

15 C1154400103

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

SUCTION COVER

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 63

GENERATOR ASSY.

DCA-220SSK — GENERATOR ASSY.

PAGE 64 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

GENERATOR ASSY.

NO PART NO

16 0017106016

0012112035

0042512000

C1132300114

0010106030

0041206000

0600815000

0605000012

003002000

004002000

DCA-220SSK — GENERATOR ASSY.

PART NAME

HEX. HEAD BOLT

LOCK WASHER

COVER, FAN

QTY.

REMARKS

HEX. HEAD BOLT

PLAIN WASHER

NUT ...................................................... 1 .......... USN6001

RUBBER SUSPENSION ...................... 2.......... EA1013

HEX. NUT

LOCK WASHER

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 65

CONTROL PANEL ASSY.

DCA-220SSK — CONTROL PANEL ASSY.

PAGE 66 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO.

PART NO.

C1225000003

C1224000503

C1224000603

0605011211

0601807622

0601806980

0601801040

0601806887

0601801041

0601810072

0601810261

0601840073

11 0601840121

120601810161

0601810214

0207004000

0601830710

C9221100004

0040008000

0041208000

0080200007

0017108040

ECU9988N

17-1

ECU88N

0601831340

0601830765

0601808716

PART NAME QTY.

REMARKS

CONTROL PANEL ......................................... 1 ............ S/N3698950~

CONTROL PANEL ......................................... 1 ............ S/N3696501 TO S/N3698949

CONTROL PANEL

FREQUENCY METER .................................. 1 ............ RSC80F 45 ~65HZ 200V

AC AMMETER .............................................. 1 ............ RSS80 0 ~400A 0 ~800A

CHANGE-OVER SWITCH ,AMMETER ......... 1 ............ SL2 AS

AC VOLTMETER ........................................... 1 ............ RSR80 0 ~600V

CHANGE OVER SWITCH, VOLTMETER ...... 1 ............ SL 2 VS

PILOT LAMP ................................................. 1 ............ LP132DC 220V

BULB ............................................................ 1 ............ CT13W

RHEOSTAT (VOLTAGE REGULATOR) .......... 1 ............ RA20A2SE102BJ 2W 1K 0HM

KNOB 1

PANEL LIGHT ............................................... 1 ............ V325070

BULB

HEX. NUT

SWITCH, PANEL LIGHT ............................... 1 ............ S301T

HEX. HEAD BOLT 2

LOCK WASHER

PLAIN WASHER

SNAP RING

HEX. HEAD BOLT

ENGINE CONTROLLER ............................... 1 ............ S/N3698950~

REPLACES 0602202545

ENGINE CONTROLLER ............................... 1 ............ S/N 696501 TO S/N3698949

REPLACES 0601827395

SWITCH ........................................................ 1 ............ S/N3696501 TO S/N3698949

SWITCH ........................................................ 1 ............ S/N3698950~

AC WATTMETER .......................................... 1 ............ S/N3698950~

PXK 80A 20 ~ 200KW

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 67

CONTROL BOX ASSY.

DCA-220SSK — CONTROL BOX ASSY.

S/N3696501 TO S/N3698949

PAGE 68 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO.

1 C1214000422

20601806133

3 0027106016

4 0601807364

4-1 0601802525

5 0601820625

6 0027105016

7 0601820892

8 0027104016

9 C1274000103

10 8181852104

11 011606025

28 LY2DC24V

PTF08A

PYCA1

PART NAME QTY. REMARKS

CONTROL BOX 1

CURRENT TRANSFORMER ................... 3......... CT5MRN 400/5A

MACHINE SCREW 6

CIRCUIT BREAKER ............................... 1......... XE600NS 600A

HANDLE, CIRCUIT BREAKER ............... 1......... S/N3696501 TO S/N3698949

AUTOMATIC VOLTAGE REGULATOR ..... 1......... NTA5A2T

MACHINE SCREW 4

OVER CURRENT RELAY ........................ 1......... THN20HZ

MACHINE SCREW 2

CHANGE- OVER BOARD, VOLTAGE 1

CHANGE TERMINAL 10

HEX. HEAD BOLT ................................. 20 ........ REPLACES 0017106025

C0277200004

8181853104

8131852504

012210020

0040010000

0041410000

011208030

TERMINAL PLATE

CHANGE PLATE

HEX. HEAD BOLT 13

HEX. HEAD BOLT ................................. 13 ........ REPLACES 0801831804

LOCK WASHER

PLAIN WASHER

HEX. HEAD BOLT ................................... 4......... S/N3698950~

REPLACES 0017108030

18 0017110030

19 C1262500014

19 C1262500004

20 011008020

HEX. HEAD BOLT ................................... 4......... S/N3696501 TO S/N3698949

SET PANEL, ELECTRIC PARTS ............ 1......... S/N3698950~

SET PANEL, ELECTRIC PARTS ............ 1......... S/N3696501 TO S/N3698949

HEX. HEAD BOLT ................................... 4......... REPLACES 0017108020

21 DYN110654000024 CONTROLLER ........................................ 1......... REPLACES 0602202598

22 DYNT11100 SPEED SENSOR .................................... 1......... REPLACES 0602120497

23 0027104020

24 0602201911

MACHINE SCREW 4

UNIT, BATTERY SENSOR ...................... 1......... C7038A00-00

25 0027106016

26 0601806671

0601802149

0601802218

27 0027104020

28 LY2US23VDC

MACHINE SCREW

FUSE (LEFT) .......................................... 1......... F106515A

FUSE (RIGHT) ........................................ 1......... F106510A

HOLDER, FUSE

MACHINE SCREW

RELAY .................................................... 1......... S/N 3698950~

REPLACES 0601827655

RELAY .................................................... 1......... S/N3696501 TO S/N3698949;

REPLACES 0601823732

SOCKET ................................................. 1......... REPLACES 0601823109

HOLDER ................................................. 1......... REPLACES 0601823109

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 69

CONTROL BOX ASSY.

DCA-220SSK — CONTROL BOX ASSY.

S/N3696501 TO S/N3698949

PAGE 70 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO.

29 0027104020

30 0601823706

31 0027104014

320601840009

33 C3262600004

34 0017106016

35 0601815402

36 0027104020

37 0601824542

38 0027103010

39 3871824004

40 0041206000

41 505015300

43 011008020

44 C1214300004

45 011008020

46 C1215400004

47 0017110025

48 0017110025

49 LC245002

50 0601850263

51 0017105016

520601808504

53 0027105020

PART NAME QTY.

REMARKS

MACHINE SCREW 2

RELAY .................................................... 1......... HE1A DC

MACHINE SCREW 2

RHEOSTAT .............................................. 1......... RA20A2SE502BJ 2W 5K OHM

BRACKET

HEX. HEAD BOLT

TERMINAL BOARD

MACHINE SCREW

RELAY .................................................... 2 ......... HH62S DC24V

MACHINE SCREW 4

STOPPER, CONTROL PANEL

PLAIN WASHER

SNAP PIN ............................................... 1......... REPLACES 0605010502

COVER, CONTROL BOX 1

HEX. HEAD BOLT ................................... 8......... REPLACES 0017108020

SIDE PANEL, CONTROL BOX 1

HEX. HEAD BOLT ................................... 4......... REPLACES 0017108020

PANEL, CONTROL BOX 1

HEX. HEAD BOLT

BATTERY CHARGER.............................. 1......... REPLACES 0601823090

GROMMET 2

HEX. HEAD BOLT 4

TRANSDUCER ........................................ 1......... S/N3698950~

MACHINE SCREW ................................. 4......... S/N3698950~

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 71

ENGINE & RADIATOR ASSY.

DCA-220SSK — ENGINE & RADIATOR ASSY.

PAGE 72 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO.

PART NO.

1 C1925200024

1-1 6125817032

1-2 6002111231

1-3 6003118293

1-4 6004111151

1-5 0602040678

20605000011

3 0030016000

0040016000

6152619720

6152619170

0010112050

0030012000

0040012000

0041212000

8195123104

0017112025

0017110025

6152621520

6152611531

0726120911

0728100809

0728100909

0728001920

3972054104

3972054304

C9601000104

011208025

0131508000

0603325017

0602022294

PART NAME QTY.

REMARKS

ENGINE ......................................................... 1 ........... KOMATSU S6D125E-2

ELEMENT, AIR CLEANER ............................ 1 ........... REPLACES 0602040156

CARTRIDGE, FUEL FILTER .......................... 1 ........... REPLACES 0602041146

CARTRIDGE, OIL FILTER ............................. 1 ........... REPLACES 0602042146

CARTRIDGE, CORROSION RESISTOR ....... 1 ........... REPLACES 0602045143

DUST SENSOR 1

RUBBER SUSPENSION

HEX. NUT

LOCK WASHER 4

RADIATOR ..................................................... 1 ........... REPLACES 0602011946

RUBBER SHEET ........................................... 2........... REPLACES 0605000490

HEX. HEAD BOLT 4

HEX. NUT

LOCK WASHER

PLAIN WASHER

BRACKET, RADIATOR

HEX. HEAD BOLT

RADIATOR HOSE .......................................... 1 ........... REPLACES 0602014513

RADIATOR HOSE .......................................... 1 ........... REPLACES 0602014641

RADIATOR HOSE .......................................... 1 ........... REPLACES 0602014541

HOSE BAND .................................................. 6 ........... REPLACES 0602014067

HOSE BAND .................................................. 2........... REPLACES 0602014056

HOSE BAND .................................................. 2........... REPLACES 0602014058

DRAIN JOINT

PACKING

DRAIN JOINT 1

HEX. HEAD BOLT ........................................... 2........... REPLACES 0017108025

NIPPLE, 3/4

VALVE

HOSE JOINT

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 73

ENGINE & RADIATOR ASSY.

DCA-220SSK — ENGINE & RADIATOR ASSY.

PAGE 74 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO.

PART NO.

27 0265800240

0605515074

0132008000

0802081003C

0802010900

32C1317100103

33 0199601300

0193601300

0193600550

0605515013

0194800750

C1325100003

0603325011

0602022293

0603320111

011008020

0207008000

0268202300

0268200650

0605515074

0605515073

C1358300814

C1358300104

012210020

0010016030

0040016000

0041216000

PART NAME

DRAIN HOSE

QTY.

REMARKS

HOSE BAND

PLUG, 3/4

RESERVE TANK ............................................. 1 ........... REPLACES 0802081003

CAP, RESERVE TANK .................................... 1 ........... REPLACES 0602010900

BRACKET, RESERVE TANK

HOSE

HOSE BAND

HOSE

OIL MIST TANK .............................................. 1 ........... S/N3698950~

VALVE 1

HOSE JOINT ................................................. 1 ........... S/N3698950~

U BOLT .......................................................... 1 ........... S/N3696501 TO S/N3698949

HEX. HEAD BOLT ........................................... 2........... S/N3698950~

REPLACES 0017108020

HEX. NUT ....................................................... 2........... S/N3696501 TO S/N3698949

HOSE .............................................................. 1 ........... S/N3698950~

BREATHER PIPE ........................................... 1 ........... S/N3696501 TO S/N3698949

HOSE 1

HOSE BAND .................................................. 4 ........... S/N3698950~

HOSE BAND .................................................. 2........... S/N3696501 TO S/N3698949; HS10

CLAMPER ROD

HEX. HEAD BOLT ........................................... 3 ........... REPLACES 0017110020

HEX. HEAD BOLT 1

LOCK WASHER

PLAIN WASHER

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 75

ENGINE OPERATING PANEL ASSY.

DCA-220SSK — ENGINE OPERATING PANEL ASSY.

PAGE 76 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO.

PART NO.

1 C1353100003

20019106016

3 0602101000

4 0021008080

020108060

0040008000

031108160

0601830710

0601831557

0601830448

6008153730

0602120054

0602120178

0602122060

0602122200

0602123061

0602123206

0602121022

0602115014

0602103091

0601810244

C1484000212

012010030

PART NAME

OPERATING PANEL

QTY.

REMARKS

HEX. HEAD BOLT 12

BATTERY SWITCH .......................................... 1 ......... 9827300090

MACHINE SCREW 2

HEX. NUT ........................................................ 2......... REPLACES 0030008000

LOCK WASHER 2

PLAIN WASHER .............................................. 4 ......... REPLACES 0041208000

ENGINE SPEED SWITCH ............................... 1 ......... S301T

EMERGENCY STOP BUTTON ........................ 1 ......... AR22V2R01R

PREHEAT BUTTON ......................................... 1 ......... AH25FB10

PREHEAT LAMP ............................................. 1 ......... REPLACES 0602102055

TACHOMETER ................................................ 1 ......... 25000KX4110

CABLE, TACHOMETER ................................... 1 ......... 62100KX0700 L=2700

OIL PRESSURE GAUGE ................................. 1 ......... 42000KX1410

UNIT, OIL PRESSURE .................................... 1 ......... 53000AC0101

WATER TEMPERATURE GAUGE .................... 1 ......... 40000KX0910

UNIT, WATER TEMPERATURE ........................ 1 ......... 751400KS0600

CHARGING AMMETER ................................... 1 ......... 43000KV0300

MONITOR ........................................................ 1 ......... V3376600000

DETECTOR LAMP, FUEL LEAK ...................... 1 ......... REPLACES 0602103090

BULB 1

SUPPORT LEG 1

HEX. HEAD BOLT ............................................ 5 ......... REPLACES 0017110030

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 77

GOVERNOR ACTUATOR ASSY.

DCA-220SSK —GOVERNOR ACTUATOR ASSY.

PAGE 78 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — GOVERNOR ACTUATOR ASSY.

GOVERNOR ACTUATOR ASSY.

NO.

PART NO.

PART NAME QTY.

REMARKS

1 DYNC11024000 ACTUATOR ...................................................... 1 ......... REPLACES 0602150091

2DYNC182 LEVER ............................................................. 1 ......... REPLACES 0602211090

C1356200004

0012310030

BRACKET, ACTUATOR

HEX. HEAD BOLT

0041210000

0010306035

0207006000

952404470

0040006000

0602211091

0602180190

0602211092

PLAIN WASHER .............................................. 4 ......... S/N3696501 TO S/N3698949

HEX. HEAD BOLT 4

HEX. NUT 4

PLAIN WASHER .............................................. 4 ......... REPLACES 0041206000

LOCK WASHER

ROD

BALL JOINT, 1/4-28

HEX. NUT

011606025

0207006000

952404470

011606025

0207006000

031110160

HEX. HEAD BOLT ............................................ 1 ......... REPLACES 0010106025

HEX. NUT 1

PLAIN WASHER .............................................. 1 ......... REPLACES 0041206000

HEX. HEAD BOLT ............................................ 1 ......... REPLACES 0010106025

HEX. NUT 1

PLAIN WASHER .............................................. 4 ......... REPLACES 0041210000

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 79

OUTPUT TERMINAL ASSY.

DCA-220SSK —OUTPUT TERMINAL ASSY.

PAGE 80 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK —OUTPUT TERMINAL ASSY.

20801030304

17 C1261600204

17-1 0223300200

OUTPUT TERMINAL ASSY.

NO.

PART NO.

1 C1231700003

0801830904

0801830804

030220510

0041420000

0039316000

0040016000

0041416000

3461860504

0019108040

030208200

031108160

0601811189

0027103010

0601812537

0027104020

0601850275

0601804887

0601805840

011206020

0601812597

0601811034

0027104016

0030004000

031104080

C1237100113

0019112045

0042412000

0805015604

0205012000

0845043704

C0237101504

014210040

0845054204

0805015604

C1237100214

011008020

PART NAME QTY.

REMARKS

SET BOARD, OUTPUT TERMINAL 1

OUTPUT TERMINAL .................................... 8 ............ S/N3698950~

OUTPUT TERMINAL .................................... 8 ............ S/N3696501TO S/N3698949

HEX. HEAD BOLT ......................................... 8 ............ S/N3698950~

HEX. HEAD BOLT ......................................... 8 ............ S/N3696501 TO S/N3698949

LOCK WASHER ............................................ 8 ............ S/N3698950~

REPLACES 0040020000

PLAIN WASHER ........................................... 8 ............ S/N3698950~

HEX. NUT

LOCK WASHER

PLAIN WASHER

TERMINAL PLATE

HEX. HEAD BOLT 5

LOCK WASHER ............................................ 5 ............ REPLACES 0042308000

PLAIN WASHER ........................................... 5 ............ REPLACES 0042408000

RECEPTACLE ............................................... 2 ............ HBL5378C 125V 20A

MACHINE SCREW 4

ADAPTER ..................................................... 1 ............ HBL5369C 125V 20A

TERMINAL BOARD

MACHINE SCREW

GROMMET 1

CIRCUIT BREAKER ..................................... 2 ............ KM51B 265V 20A

REPLACES 0601805313

CIRCUIT BREAKER ..................................... 3 ............ KM52265V 50A

BRACKET, CIRCUIT BREAKER

RUBBER CUSHION

HEX. HEAD BOLT ......................................... 2............ REPLACES 0017106020

RECEPTACLE ............................................... 2............ GF530EM

REPLACES 0601812598

RECEPTACLE ............................................... 2............ CS6369

REPLACES 0601812565

MACHINE SCREW 10

HEX. NUT 10

PLAIN WASHER .......................................... 10 ........... REPLACES 0041204000

COVER, OUTPUT TERMINAL

HEX. HEAD BOLT

PLAIN WASHER

STAY RUBBER

HEX. NUT

SPRING

COVER 1

HEX. HEAD BOLT ......................................... 2............ REPLACES 0017110040

COLLAR

STAY RUBBER

COVER 1

HEX.HEAD BOLT ......................................... 7 ............ REPLACES 0017108020

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 81

BATTERY ASSY.

DCA-220SSK — BATTERY ASSY.

PAGE 82 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — BATTERY ASSY.

BATTERY ASSY.

NO.

PART NO.

1 0168614551

20805000804

0805000904

0805002904

0037808000

0041208000

C1347600004

C1347600104

C1347600504

C1347600304

0347010030

0208110000

0845040414

0845041304

0602220203

0010110020

0040010000

031110160

0040510000

PART NAME QTY.

REMARKS

BATTERY ....................................................... 2........... 145G51

BATTERY SHEET 2

BATTERY BAND

BATTERY BOLT

WING NUT

PLAIN WASHER

BATTERY CABLE

EARTH CABLE

HEX. HEAD BOLT

HEX.NUT

TERMINAL CAP (+)

TERMINAL CAP (-) 2

BATTERY SENSOR ....................................... 1 ........... REPLACES 0602220204

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER ............................................. 1 ........... REPLACES 0041610000

TOOTHED WASHER 1

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 83

MUFFLER ASSY.

DCA-220SSK — MUFFLER ASSY.

PAGE 84 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — MUFFLER ASSY.

MUFFLER ASSY.

NO.

PART NO.

1 C1331100702

0019210025

C1334000403

150115751

C1334200304

0010312050

0030312000

0040012000

031112230

7 0010312055

0030312000

0040012000

031112230

C1331300104

C1334200104

011008020

C1334300104

0603320129

0207010000

PART NAME

MUFFLER

QTY.

REMARKS

HEX. HEAD BOLT

EXHAUST PIPE

GASKET ........................................................ 1 ........... REPLACES 0602320142

GASKET 1

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER 4

PLAIN WASHER ............................................. 8 ........... REPLACES 0041212000

HEX. HEAD BOLT

HEX NUT

LOCK WASHER 4

PLAIN WASHER ............................................. 8 ........... REPLACES 0041212000

COVER

SHEET

HEX. HEAD BOLT ........................................... 4 ........... REPLACES 0017108020

BRACKET 1

HEX. HEAD BOLT ........................................... 4 ........... REPLACES 0017108020

U BOLT 2

HEX. NUT 4

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 85

FUEL WATER SEPARATOR ASSY.

S/N3698950~

DCA-220SSK —FUEL WATER SEPARATOR ASSY.

PAGE 86 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — FUEL WATER SEPARATOR ASSY.

FUEL WATER SEPARATOR ASSY. S/N3698950~

NO.

PART NO.

1 75500FGX

R2010PMOR

1-1 RK19476

2C036870004

C9202000604

011008020

0191000620

0605515013

91108H6

91108H10

LGX500

C9202000304

0130206000

0602022293

0017106040

C4368700104

0602022284

0602022203

0017110025

0191300800

0191500600

0191501600

0191302600

0605515109

0605515074

PART NAME QTY.

REMARKS

WATER SEPARATOR ..................................... 1 ........... REPLACES 0602042270

ELEMENT, WATER SEPARATOR 2

PRESSURE GAUGE ..................................... 1 ........... REPLACES 0602130190

BRACKET, PRESSURE GAUGE 1

HOSE JOINT 2

HEX. HEAD BOLT ......................................... 4 ............ REPLACES 0017108020

HOSE

HOSE BAND

HOSE JOINT ................................................. 1 ........... REPLACES 0602022787

HOSE JOINT ................................................. 1 ........... REPLACES 0602022786

FUEL CONDITIONER .................................... 1 ........... REPLACES 0602042490

ADAPTER 2

STREET ELBOW, 1/22

HOSE JOINT 2

HEX. HEAD BOLT

BRACKET

HOSE JOINT

HEX. HEAD BOLT

SUCTION HOSE

RETURN HOSE

HOSE BAND

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 87

FUEL WATER SEPARATOR ASSY.

S/N3696501TO S/N3698949

DCA-220SSK —FUEL WATER SEPARATOR ASSY.

PAGE 88 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — FUEL WATER SEPARATOR ASSY.

FUEL WATER SEPARATOR ASSY. S/N3696501 TO S/N3698949

NO.

PART NO.

1 230R

R30P

2C1368700004

3 0017110025

0017108030

0603306495

C9202000004

0130008000

0602022284

C4368700104

0017110025

0602022203

120191300600

13 0191502800

0191302600

0605515109

0605515074

PART NAME QTY.

REMARKS

WATER SEPARATOR ....................... 1 ................REPLACES 0602042286

ELEMENT, WATER SEPARATOR ..... 1 ................REPLACES 0602042287

BRACKET, WATER SEPARATOR 1

HEX. HEAD BOLT 2

HEX.HEAD BOLT

ELBOT JOINT

JOINT

ELBOW JOINT, 3/4

HOSE JOINT

BRACKET

HEX. HEAD BOLT

HOSE JOINT

SUCTION HOSE

RETURN HOSE

HOSE BAND

HOSE HAND

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 89

JACKET WATER HEATER ASSY.

DCA-220SSK-JACKET WATER HEATER ASSY.

PAGE 90 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK-JACKET WATER HEATER ASSY.

JACKET WATER HEATER ASSY.

NO.

PART NO.

1 SB1151100000

PART NAME QTY.

REMARKS

WATER HEATER ............................................. 1 ........... REPLACES 0602014293

011206020

0603307690

HEX. HEAD BOLT ........................................... 4 ........... REPLACES 0017106020

SOCKET ......................................................... 1 ........... NPT1

0603306892

0603306293

C1322700004

6150211190

BUSHING ....................................................... 1 ........... NPT1X3/8

STREET ELBOW ........................................... 1 ........... 3/8

ADAPTER 1

O RING .......................................................... 1 ........... REPLACES 0602021157

0603306312

0603306223

0603325076

0602022292

C1322700104

C1322700204

0265700600

0605515074

NIPPLE

STREET ELBOW

VALVE

HOSE JOINT

HOSE ............................................................. 1 ........... S/N3698950~

HOSE ............................................................. 1 ........... S/N3696501 TO S/N3698949

HOSE ............................................................. 1 ........... S/N3698950~

HOSE ............................................................. 1 ........... S/N3696501 TO S/N3698949

HOSE BAND 4

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 91

ENCLOSURE ASSY.

DCA-220SSK — ENCLOSURE ASSY.

PAGE 92 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

1 C1415000022

C1415000012

C1415000002

C1494000104

20601851733

C3414100004

011008020

C1425000002

C1495100003

C1424000602

C1494100403

0019210025

C1425200004

8175924104

011008020

C1424200503

011008020

C1435000002

C1434000202

120010114050

020114110

030214350

031114260

0010120050

0030020000

030220510

0041220000

C1444000412

C1494300504

0019210025

C1444300403

C1494300304

C1444300303

C1494300404

020108060

011008020

C1444200103

8175143303

8225147004

020106050

B9114500104

0207006000

PART NAME QTY.

REMARKS

BASE ....................................................................... 1 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

BASE ....................................................................... 1 .......... S/N3698950 TO S/N3699126

BASE ....................................................................... 1 .......... S/N3696501 TO S/N3698949

LINING 2

GROMMET 2

FLOOR PANEL 1

HEX. HEAD BOLT ................................................ 10 .......... REPLACES 0019208020

FRONT FRAME ..................................................... 1 .......... S/N3698950~

LINING .................................................................... 1 .......... S/N3698950~

FRONT FRAME ..................................................... 1 .......... S/N3696501 TO S/N3698949

LINING .................................................................... 1 .......... S/N3696501 TO S/N3698949

HEX. HEAD BOLT

COVER, FRONT FRAME

LINING

HEX. HEAD BOLT ................................................ 21 .......... REPLACES 0019208020

COVER, FRONT FRAME 1

HEX. HEAD BOLT ................................................ 14 .......... REPLACES 0019208020

CENTER FRAME ................................................... 1 .......... S/N3698950~

CENTER FRAME ................................................... 1 .......... S/N3696501 TO S/N3698949

HEX. HEAD BOLT 4

HEX. NUT ................................................................ 4 .......... REPLACES 0030014000

LOCK WASHER ..................................................... 4 .......... REPLACES 0040014000

PLAIN WASHER ..................................................... 8 .......... REPLACES 0041214000

HEX. HEAD BOLT

HEX. NUT

LOCK WASHER ..................................................... 4 .......... REPLACES 0040020000

PLAIN WASHER

REAR FRAME

LINING

HEX. HEAD BOLT

COVER, REAR FRAME

LINING

DUCT

LINING

HEX. NUT .............................................................. 12.......... REPLACES 0207008000

HEX. HEAD BOLT ................................................ 17 .......... REPLACES 0019208020

DOOR, REAR FRAME

WINDOW PLATE 2

HEX. NUT .............................................................. 12.......... REPLACES 0037906000

DOOR POCKET

HEX. NUT

ADD THE FOLLOWING LETTERS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

MQW- WHITE

MQG-GREY

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 93

ENCLOSURE ASSY.

DCA-220SSK — ENCLOSURE ASSY.

PAGE 94 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

B9114000102

0021806016

020106050

8175146204

8175146304

0845050704

0205006000

0042306000

0042406000

320805011304

0805011204

0207006000

M911060204

0845045004

M9110100304

0845045004

011008020

C1465100002

C1495500004

C1464100102

C1494500204

0800251701

0025006016

0042306000

0042406000

C1464200002

C1494500004

C0044508019

C1455200002

0019108065

0019108070

030208200

031108160

0044508019

PART NAME QTY.

REMARKS

DOOR HANDLE 1

MACHINE SCREW 4

HEX. NUT ................................................................ 4 .......... REPLACES 0030006000

S/N3698950 TO S/N3699126

DOOR ROD

STAY

HEX. NUT

LOCK WASHER

PLAIN WASHER

STOPPER, DOOR

HEX. NUT

HINGE ..................................................................... 2.......... REPLACES 0845047104

WASHER 2

HINGE ..................................................................... 2.......... REPLACES 0845047204

WASHER 2

HEX. HEAD BOLT .................................................. 6 .......... REPLACES 0019208020

ROOF PANEL ......................................................... 1 .......... S/N3698950~

LINING .................................................................... 1 .......... S/N3698950~

ROOF PANEL ......................................................... 1 .......... S/N3696501 TO S/N3698949

LINING .................................................................... 1 .......... S/N3696501 TO 3698949

FILLER COVER

MACHINE SCREW

LOCK WASHER

PLAIN WASHER

ROOF PANEL

LINING

HEX. HEAD BOLT ................................................ 40 .......... REPLACES 0019208020

SEAL WASHER .................................................... 40 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

SPLASHER PANEL 1

HEX.HEAD BOLT ................................................... 6 .......... S/N3696501 TO S/N3699126

HEX. HEAD BOLT .................................................. 6 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

LOCK WASHER ..................................................... 6 .......... REPLACES 0042308000

PLAIN WASHER ..................................................... 6 .......... REPLACES 0042408000

SEAL WASHER ...................................................... 6 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

ADD THE FOLLOWING LETTERS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

MQW- WHITE

MQG-GREY

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 95

ENCLOSURE ASSY.

DCA-220SSK — ENCLOSURE ASSY.

PAGE 96 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

NO.

PART NO.

C1454000903

C1455000503

C1494401604

C1454001003

C1455000603

C1494401704

C1454001203

C1494401804

C1454001103

C1455000703

C1494401904

C1454300604

C1494402904

C1454300604

C1494402104

C1454300704

C1494402004

B9114000002

C9312500004

0825007362

C931250004

55 0021806016

020106050

0845046904

0845045004

0845047004

0845045004

011008020

0601850097

011208025

0845031504

62C1445500004

C1455600104

C1455600004

0021906016

DCA-220SSK — ENCLOSURE ASSY.

PART NAME QTY.

REMARKS

SIDE DOOR ............................................................ 1 .......... S/N3696501 TO 3699126

SIDE DOOR ............................................................ 1 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

LINING 1

SIDE DOOR ............................................................ 1 .......... S/N3696501 TO S/N3699126

SIDE DOOR ............................................................ 1 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

LINING 1

SIDE DOOR

LINING

SIDE DOOR ............................................................ 1 .......... S/N3696501 TO S/N3699126

SIDE DOOR ............................................................ 1 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

LINING 1

DUCT

LINING

DUCT

LINING

DUCT

LINING

HEX. NUT .............................................................. 19 .......... REPLACES 0207008000

DOOR HANDLE 4

RUBBER SEAL ....................................................... 4 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

DOOR HANDLE 3

RUBBER SEAL ....................................................... 3 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

MACHINE SCREW 28

HEX. NUT .............................................................. 28 .......... REPLACES 0030006000

S/N3696501 TO S/N3699126

HINGE

WASHER

HINGE

WASHER

HEX. HEAD BOLT ................................................ 25 .......... REPLACES 0019208020

STOPPER 10

MACHINE SCREW ............................................... 10 .......... REPLACES 0021008025

CAP 15

COVER BRACKET ................................................ 1 ........... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

DOOR BRACKET ................................................... 2.......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

DOOR BRACKET ................................................... 1 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

MACHINE SCREW ................................................. 9 .......... S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

ADD THE FOLLOWING LETTERS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

MQW- WHITE

MQG-GREY

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 97

RUBBER SEALS ASSY.

DCA-220SSK-RUBBER SEAL ASSY.

PAGE 98 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK-RUBBER SEAL ASSY.

RUBBER SEALS ASSY.

NO.

PART NO.

1 0229201300

0228901010

0228901250

0228901050

0228900650

0229200950

0228901280

0229201200

0228801100

0221200760

0228100510

0228100120

0229200600

0229201040

0226900990

0226903525

0226903440

0226901030

0220301030

0226901270

PART NAME

RUBBER SEAL

QTY.

REMARKS

RUBBER SEAL

RUBBER SEAL 4

RUBBER SEAL ...................... 2........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 1 ........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 2........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 2........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 1 ........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 1 ........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 1 ........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

RUBBER SEAL ...................... 2........................ S/N3699127 TO S/N3699149

S/N3699620 TO S/N3699636

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 99

DECALS ASSY.

DCA-220SSK-DECALS ASSY.

PAGE 100 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK-DECALS ASSY.

DECALS ASSY.

NO.

1-1

2-1 0800520100

2-2 0800520904

2-3 0800520814

2-4 0840624504

2-5 0840624604

2-6 0840624704

2-7 0840624804

2-8 B9531100604

2-9 C0551000903

2-10 C2551000004

2-11 C0561101603

3-1 1320610603

3-26360610304

3-3 6360620204

3-4 B9504000304

3-5 B9504000404

3-6 B9504100104

3-7 C9542200004

3-8 C9542200104

3-9 C9542200204

4-1

4-3

5-1

5-3

5-4

5-5

5-6

5-7

PART NO.

C1552000403

C0551000504

C1552000104

0840614104

5-20840619904

9039209064

B9511100304

B9511100404

B9531100504

C0551000404

PART NAME QTY.

REMARKS

DECAL; HANDLING PROCEDURES .................................. 1............ C15200040

DECAL; CAUTION ............................................................... 2............ B15200010

CONTROL BOX GROUP

DECAL; ON-OFF ................................................................. 1............ AT- 202

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

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

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

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

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

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

DECAL; WARNING ELECTRIC SHOCK HAZARD .............. 2............ B9311 0060

DECAL; SETTING FOR OUTPUT VOLTAGE ...................... 1............ C0510 0090

DECAL; SAFETY INSTRUCTIONS ..................................... 1............ C2510 0000

DECAL; WHISPERWATT 220 .............................................. 1............ C1611 0160

ENGINE & RADIATOR GROUP

DECAL; WATER - OIL ........................................................ 1............ S/N 3698950~

S- 1760

DECAL; WATER .................................................................. 1............ S- 1880

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

DECAL; CAUTION HOT PARTS .......................................... 1............ S/N 3698950~

B9040 0040

DECAL; WARNING MOVING PARTS .................................. 2............ B9040 0040

DECAL; WARNING HOT COOLANT .................................... 1............ B9041 0010

DECAL; BLOW-BY OIL MIST DRAIN DAILY ....................... 1............ S/N 3698950~

C9422 0000

DECAL; BLOW-BY OIL MIST TANK .................................... 1............ S/N 3698950~

C9422 0010

DECAL; INLET .................................................................... 1............ C9422 0020

ENGINE OPERATING PANEL GROUP

DECAL; BATTERY SWITCH ............................................... 1............ C0510 0050

DECAL; OPERATING PANEL ............................................. 1............ C1520 0001

DECAL; FUEL LEAK DETECTED ....................................... 1............ C1520 0010

OUTPUT TERMINAL GROUP

DECAL; GROUND ............................................................... 1............ S- 2635

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

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

DECAL; WARNING .............................................................. 1............ B9111 0030

DECAL; WARNING ELECTRIC SHOCK HAZARD .............. 1............ B9111 0040

DECAL; WARNING ELECTRIC SHOCK HAZARD .............. 1............ B9311 0050

DECAL; 3- PHASE OUTPUT TERMINAL ........................... 1............ C0510 0040

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 101

DECALS ASSY.

DCA-220SSK-DECALS ASSY.

PAGE 102 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)

DCA-220SSK-DECALS ASSY.

DECALS ASSY.

NO.

PART NO.

5-8 C0551001503

5-9 C1552000204

5-10 C1552000304

6-1

8-3

0800689404

6-20800689504

6-3

7-1

8-1

8-20800688504

8-4

9-1

C9595300004

B9504200004

0800688404

1320620904

B9504500004

1320621504

9-20600500090

0021106016

PART NAME QTY.

REMARKS

DECAL; RECEPTACLE & CIRCUIT BREAKER .................. 1............ C0510 0150

DECAL; WATER HEATER ................................................... 1............ C1520 0020

DECAL; BATTERY CHARGER ............................................ 1............ C1520 0030

BATTERY GROUP

DECAL; + ............................................................................ 1............ S- 2090

DECAL; - ............................................................................. 1............ S- 2091

DECAL; CAUTION ............................................................... 1............ C9053 0000

MUFFLER GROUP

DECAL; WARNING ENGINE EXHAUST ............................. 1............ B9042 0000

FUEL PIPING GROUP

DECAL; FUEL INLET .......................................................... 1............ S- 1344

DECAL; FUEL OUTLET ...................................................... 1............ S- 1345

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

DECAL; WARNING DIESEL FUEL ...................................... 1............ B9045 0000

BONNET GROUP

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

EMBLEM 2

MACHINE SCREW 4

DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01) — PAGE 103

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

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

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

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

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

The list must be typed or computer generated.

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

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

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

A copy of the Return Material

Authorization must accompany the return shipment.

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

Multiquip’s designated receiving point.

Parts must be in new and resalable condition, in the original Multiquip package

(if any), and with Muiltiquip part numbers clearly marked.

The following items are not returnable: a.

Obsolete parts. (If an item is listed in the parts price book 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.

Any line item with an extended dealer net price of less than $5.00.

Special order items.

Electrical components.

Paint, chemicals, and lubricants.

Decals and paper products.

Items purchased in kits.

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

Such material will be held for 5 working days from notification, pending instructions. If a reply is not received within 5 days, the material will be returned to the sender at his expense.

Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge.

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 $20.00 to $50.00 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. A part 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.

PAGE 104 — DCA-220SSK — PARTS AND OPERATION MANUAL (GEER)— REV. #1 (03/14/01)