MQ Power DCA150SSK2, Portable Generator DCA-150SSKII User manual

MQ Power DCA150SSK2, Portable Generator DCA-150SSKII User manual
PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
Table of Contents
© COPYRIGHT 2000, MULTIQUIP INC.
MQ POWER
MODEL DCA-150SSKII
PORTABLE GENERATOR
Revision #2 (05/08/01)
MULTIQUIP INC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
SERVICE DEPARTMENT:
310-537-3700
800-421-1244
800-835-2551
FAX: 310-537-3927
FAX: 310-638-8046
E-mail:[email protected] • www:multiquip.com
Table of Contents
PAGE 2 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ...........................................3
Table Of Contents ....................................................4
Parts Ordering Procedures ......................................5
Rules For Safe Operation .................................... 6-9
Towing ....................................................................10
Trailer Safety Guidlines ..........................................11
Trailer Specifications ........................................ 12-13
Trailer Braking System ..................................... 14-15
Trailer Tires & Suspension ............................... 16-17
Trailer Wire Diagram ..............................................18
Trailer Electric Brakes Troubleshooting ..................19
Trailer Hydraulic Brakes Troubleshooting...............20
Operation And Safety Decals ........................... 21-22
Specifications .........................................................23
General Information ...............................................24
Generator Assembly .......................................... 60-61
Control Box Assembly ........................................ 62-65
Engine Radiator Assembly ................................. 66-69
Engine Operating Panel Assembly .................... 70-73
Battery Assembly ............................................... 74-75
Muffler Assembly ............................................... 76-77
Fuel Tank Assembly ........................................... 78-79
Enclosure Assembly ........................................... 80-83
Enclosure (Rubber Seals) .................................. 84-85
Name Plate and Decals ..................................... 86-89
Terms and Conditions Of Sale — Parts ...................90
MQ Power DCA-150SSKII
AC Generator
Major Components ................................................26
Dimensions (Top, Side And Rear)..........................27
Control Panel.................................................... 28-29
Engine Operating Panel ................................... 30-31
Output Terminal Panel ...................................... 32-39
Installation ........................................................ 40-41
Pre-Setup ......................................................... 42-45
Load Application ....................................................46
Generator Start-Up Procedure (Manual) ......... 47-49
Generator Start-Up Procedure (Auto) ...................50
Generator Shut-Down Procedure ..........................51
Maintenance .................................................... 51-53
Troubleshooting (Engine) ................................. 54-55
Troubleshooting (Generator/Engine) .....................56
Troubleshooting (MPEC) ........................................57
Explanation Of Codes In Remarks Column ...........58
Suggested Spare Parts ..........................................59
NOTE
Specification and part
number are subject to
change without notice.
PAGE 4 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
PARTS ORDERING PROCEDURES
■
■
■
■
■
■
■
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
•
•
•
•
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
•
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
1-9 items
Additional Discount
3%
10+ items**
5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■ UPS Ground Service at no charge for freight
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
ount
c
s
i
D
Fax
Extra
c USA
i
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s
e
m
for Do
Only
s
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a
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UPS l
Specia
only
orders
d
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For
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 5
Table of Contents
RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained
and qualified personnel only! This equipment
is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-150SSKII portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
reading this entire manual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVER operate this equipment without proper
protective clothing, shatterproof glasses,
steel-toed boots and other protective
devices required by the job.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ 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.
■ Manufacture 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.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
■ The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricted it will cause serious
damage to the generator or
engine and may cause injury
to people. Remember the
generator engine gives off
DEADLY carbon monoxide
gas.
CAUTION:
Always refuel in a well-ventilated area,
away from sparks and open flames.
■ 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-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
RULES FOR SAFE OPERATION
CAUTION:
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.
■ DO NOT touch output terminals during operation. This is
extremely dangerous when your hands are wet. Always
stop the machine when contact with the output terminals
is required.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot will result in boiling water to gush out of
the radiator, therefore causing severe scalding to any
persons in the general area of the generator.
CAUTION:
■ 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 the
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-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 7
Table of Contents
RULES FOR SAFE OPERATION
Battery
CAUTION:
Never over fill the battery with water above
the upper limit.
■ NEVER Run engine without an 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.
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:
■ 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.
1. DO NOT drop the battery. There is the possibility 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.
■ 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.
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-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
RULES FOR SAFE OPERATION
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
Maintenance Safety
■ NEVER lubricate components or attempt service on a
running generator.
■ Drain fuel when transporting generator over long distances
or bad roads.
■ Always allow the engine proper amount of time to cool
before servicing.
■ Always tie-down the generator during transportation by
securing the generator.
■ Keep the generator in proper running condition.
■ 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.
■ Fix damage to the generator 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-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 9
Table of Contents
DCA-150SSKII — TOWING
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
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 that the
trailer that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of 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 the towing vehicle
and the trailer. Also check the tire tread wear on both
vehicles.
■ ALWAYS make sure that the vehicle and trailer
directional, backup, brake, and trailer lights are
connected properly and are 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.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
PAGE 10 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TRAILER-SAFETY GUIDELINES
CAUTION:
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
ALWAYS make sure the trailer is in good
(10,12,14, etc.), and the width in millimeters
operating condition. Check the tires for
(175,185,205, etc.). The tire diameter must match the
proper inflation and wear. Also check the
diameter of the tire rim.
wheel lug nuts for proper tightness.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
Explanation of Chart:
axle.
This section is intended to provide the user with trailer service and maintenance information. The service and main- 11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
tenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer 12. Lug Nuts - Used to secure the wheel to the wheel hub.
will ensure safe towing of the equipment and will prevent
Always use a torque wrench to tighten down the lug
damage to the equipment and personal injury.
nuts. See Table 4 and Figure 5 for lug nut tightening and
sequence.
It is the purpose of this section to cover the major mainte- 13. Axle - Indicates the maximum weight the axle can supnance components of the trailer. The following trailer comport in pounds, and the diameter of the axle expressed
ponents will be discussed in thie section:
in inches (see Table 3 on page 17). Please not that
some trailers have a double axle. This will be shown as
! Brakes
2-6000 lbs., meaning two axles with a total weight ca! Tires
pacity of 6000 pounds.
! Lug Nut Torquing
14. Suspension - Protects the trailer chassis from shock
! Suspension
transmitted through the wheels. Types of suspension
! Electrical
used are leaf, Q-flex, and air ride.
! Brake Troubleshooting Tables
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
Use the following definitions while reading Table1.
be connected to the towing vehicle. See page 16 for
1. Fuel Cell - Provides an adequate amount of fuel for
proper wiring connections.
the equipment in use. Fuel cells must be empty when
16. Application - Indicates which units can be employed
transporting equipment.
on a particular trailer.
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.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 11
Table of Contents
DCA-150SSKII — TRAILER-SPECIFICATIONS
Table 1. Specifications
MOD EL
APPLIC ATION
FU E L
C E LL
B R AK E
SYSTEM
GVWR
FR AME
LEN GTH
FR AME
WID TH
JAC K
STAN D
TR LR -10-15
TLG-12, D C A15,
TLW-300
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TR LR -10X
TLG-12, D C A15,
TLW-300
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TR LR -10XF
TLG-12, D C A15,
TLW-300
51 GAL
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TR LR -225W
D C A-10
NO
NO
2200LB S
85"
42"
800LB .
FULL TILT WHEEL
B LW-400
BLW-400
NO
ELEC TRIC
2700LB S
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB .
FULL TILT WHEEL
TR LR -15XF
D C A-15
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TR LR -50X
D C A-25
NO
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TR LR -50XF
D C A-25
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TR LR -25SB T
D C A-25
NO
NO
2990LB S
120"
66"
800LB .
FULL TILT WHEEL
TR LR -70W
D C A-45, -60, 70
NO
SURGE
7000LB S
186"
77"
2000LB .
FLAT PAD
TR LR -70X
D C A-45, -60, 70
OPT
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TR LR -70XF
D C A-45, -60, 70
53 GAL
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TR LR -100XF
D C A-100, 125
150 GAL
HYD RAULIC SURGE
7000LB S
190"
76"
2000LB .
FLAT PAD
TR LR -85/125
D C A-85, 100,
125
145 GAL
HYD RAULIC
10000LB S
186"
77"
2000LB .
FLAT PAD
TR LR -150XF
D C A-150, 180
200 GAL
HYD RAULIC SURGE
11160LBS
204"
84"
5000 LB .
FLAT PAD
TR LR -220XF
D C A-220
250 GAL
HYD RAULIC SURGE
14000LB S
222"
83"
5000 LB .
FLAT PAD
TR LR -300XF
D C A-300
250 GAL
HYD RAULIC SURGE
18000LB S
238"
83"
5000 LB .
FLAT PAD
TR LR -400XF
D C A-400
350 GAL
ELEC TRIC
18000LB S
238"
83"
5000 LB .
FLAT PAD
TR LR -600XF
D C A-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
TR LR -800SX
D C A-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
PAGE 12 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10-15W
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X 2
5 LUG
3 LE A F
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10X
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-10XF
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-225W
2" B A LL C LA S S
2 ADJUSTABLE
175-13B
13X4.5"
2200#2X 2
5 LUG
Q F LE X
4 POLE FLAT
BLW 400
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13 X 4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-15XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500# 2-1/2"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-50X
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-50XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-70W
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70X
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70XF
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-100XF
ADJUSTABLE 2-5/6
OPT 3" EYE
205-15C
BIAS (4)
14"X5.5"
3500lbs
3"
5 LUG
5 LE A F
4 WIRE LOOM
TRLR-85/125
ADJUSTABLE 2-5/6
OPT 3" EYE
ST225/75R15D
RADIAL (4)
14"x6"
(2)-6000lbs
6 LUG
7 LE A F
4 WIRE LOOM
TRLR-150XF
3" BALL EYE
750-16 E
BIAS (4)
16" X 7"
(2)-6000lbs
8 LUG
7 LE A F
4 WIRE LOOM
TRLR-220XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16" X 7"
(2)-7000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-300XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(2)-6000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-400XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(3)-7000lbs.
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-600XF
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
7 LE A F
6 WIRE LOOM
TRLR-800AR
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
AIR-RIDE
6 WIRE LOOM
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 13
Table of Contents
DCA-150SSKII — TRAILER BRAKING SYSTEM
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:
! An electric brake system can be manually adjusted to
provide the corrected braking capability for varying road
and load conditions.
! An electric brake system can be modulated to provide
more or less braking force, thus easing the brake load
on the towing vehicle.
! An electric brake system has very little lag time between
the time the vehicle’s brakes are actuated and the
trailer’s brakes are actuated.
! An electric brake system can provide an independent
emergency brake system.
Road testing is necessarry in order to properly synchronize
the towing vehicle’s braking to the trailer’s braking. 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. Refer to Table 5 for electric
brake troubleshooting guidelines.
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-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TRAILER BRAKING SYSTEM
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.
Figure 3 below displays the major hydraulic/air/surge brake
components that will requrie inspection and maintenance.
Inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section. Refer to Table 6 for hydraulic brake troubleshooting
guidelines.
Figure 3. Hydraulic Brake Components
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 15
Table of Contents
DCA-150SSKII — TRAILER TIRES & SUSPENSION
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 attempt to repair or modify a
wheel. DO NOT install an inner tube to
correct a leak through the rim. If the
rim is cracked, the air pressure in the
inner tube may cause pieces of the rim
to explode (break off) with great force and cause serious
eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in
preserving tire life. Pressure should be checked cold before
operation. DO NOT bleed air from tires when they are hot.
Check inflation pressure weekly to insure the maximum
tire life and to prevent premature 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:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
Figure 4. Suspension Components
PAGE 16 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TRAILER TIRES & SUSPENSION
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
MIN-30 MAX-35
7/16" U-BOLT
MIN-45 MAX-60
1/2" U-BOLT
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
SPRING EYE BOLT
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
MIN-30 MAX-50
SHOULDER TYPE
SHACKLE BOLT
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
4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically for continued safe
operaion.
Table 4. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
Figure 5. Lug Nut Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 17
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DCA-150SSKII — TRAILER WIRING DIAGRAMS
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — TRAILER-BRAKE TROUBLESHOOTING
Table 5. Electric Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes or Intermittent Brakes
Any open circuits or broken wires?
Find and correct.
Any short circuits?
Find and correct.
Faulty controller?
Test and correct.
Any loose connections?
Find and repair.
Ground wire secure?
Find and secure.
Grease or oil on magnets or linings?
Clean or replace.
Connections corroded?
Clean and correct cause
of corrosion.
Brake drums scored or grooved?
Machine or replace.
Brakes synchronized?
Correct.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Bearings of the wheel adjusted?
Adjust.
Weak Brakes or Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging Brakes
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 19
Table of Contents
DCA-150SSKII — TRAILER-BRAKE TROUBLESHOOTING
Table 6. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Weak Brakes or Brakes Pull to
One Side
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Brake drums scored or grooved?
Machine or replace.
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the same axle?
Match tires.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness correct or in right
wrong position?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber parts
fill with dot4 fluid.
Locking Brakes
Noisy Brakes
Dragging Brakes
PAGE 20 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-150SSKII 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 page shows these decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your
dealer.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 21
Table of Contents
DCA-150SSKII — OPERATION AND SAFETY DECALS
PAGE 22 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — SPECIFICATIONS
Table 7. Speci fi cati ons
Generator Speci fi cati ons
Model
D C A-150SSKII
Type
Revolvi ng fi eld, self venti lated, open protected type
synchronous generator
Armature C onnecti on
Star w ith N eutral
Zig Zag
Phase
3
Si ngle
Standby Output
165 KVA (132 KW)
96K W
Pri me Output
150 KVA (120 KW)
87K W
Voltage
240V or 480V
240V
Frequency
60 Hz
S peed
1800 rpm
Power Factor
0.8
1
Aux. AC Power
Si ngle Phase, 60 Hz
Voltage
120 V
Output
4.8 KW (2.4 KW x 2)
Engi ne Speci fi cati ons
Model
KOMATSU S6D 108E-2
Type
4-cycle, water-cooled, di rect i njecti on, turbo-charged
No. of C yli nders
6 cyli nders
Bore x Stroke
4.25 i n. x 5.11 i n. (108 mm x 130 mm)
Rated Output
180HP/1800 rpm
D i splacement
436 cu. i n. (7150 cc)
Starti ng
Electri c
C oolant C apaci ty
7.4 gal. (28 li ters)
Lube Oi l C apaci ty
6.6 gal. (25 li ters)
9.2 gal. (34.8L)/hr at full
load
6.9 gal. (26.1L)/hr at 3/4 load
4.8 gal. (18.2L)/hr at 1/2
load
3.2 gal. (12.1L)/hr at 1/4 load
Fuel C onsumpti on
Battery
12V- 120AHx2
Fuel
#2 D i esel Fuel
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 23
Table of Contents
DCA-150SSKII — GENERAL INFORMATION
DCA-150SSKII FAMILIARIZATION
Generator
The MQ Power Model DCA-150SSKII is a 120 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.
Microprocessor Controlled Alarm System
The DCA-150SSKII 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-150SSKII
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.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
" Tachometer
" Water Temperature Gauge
" Oil Pressure Gauge
" Charging Ammeter Gauge
" Engine Warning Lamp Module
" Engine Throttle Lever
" Pre-Heat Button
" Pre-Heat Lamp
Generator Control Panel
The “Generator Control Panel” is provided with the following:
" Output Voltage Adjustment Knob
" Frequency Meter (Hz)
" AC Ammeter (Amps)
" AC Voltmeter (Volts)
" Ammeter Change-Over Switch
" Voltmeter Change-Over Switch
" Panel Light
" Panel Light Switch
" MPEC Module
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
"
"
"
"
Three 240/139V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 265V @65 amps
2 Load GFCI Circuit Breakers [email protected] 20amps
Control Box
The “Control Box” is provided with the following:
" Main Circuit Breaker 400 amps
" Over-Current Relay
Open Delta Excitation System
The DCA-150SSKII 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.
Engine
The DCA-150SSKII is powered by a 4-cycle water cooled,
turbocharged KOMATSU Model S6D108E-2 diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 1, page 13
for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-150SSKII
generator are addressed on the following pages.
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NOTE PAGE
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 25
Table of Contents
DCA-150SSKII — MAJOR COMPONENTS
Figure 6. Major Components
PAGE 26 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — DIMENSIONS (TOP, SIDE, AND REAR)
Figure 7. Dimensions
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 27
Table of Contents
DCA-150SSKII — CONTROL PANEL
Figure 8. Control Panel
PAGE 28 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-150SSKII " Control Panel "(Figure 8).
1.
Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
2.
AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
3.
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.
4.
AC Voltmeter – Indicates the single phase output
voltage present at the UNV terminals.
5.
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.
6.
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.
7.
8.
Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage
9.
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 – Microprocessor Engine Control Module –
(MPEC) has a vertical row of status LED's (Figure 9),
that when lit, indicate that a engine malfunction (fault),
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.
A. Off/Manual/Auto Switch – This switch controls the
running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the manual position, the generator will start
immediately.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the auto position. In this position the
generator will monitor the AC line output from the
building's power source.
B. Low Oil Pressure – Indicates the engine pressure
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a major fault.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
D. Overcrank Shutdown – Indicates the unit has
attempted to be started 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.
E. Overspeed Shutdown – Indicates that 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.
Figure 9. MPEC Module
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 29
Table of Contents
DCA-150SSKII — ENGINE OPERATING PANEL
Figure 10. Engine Operating Panel
PAGE 30 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA150SSKII — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-150SSKII " Engine Operating Panel "(Figure 10).
1.
Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
2.
Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
3.
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.
4.
Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
5.
Fuel Gauge - Indicates amount of diesel fuel available.
6.
Engine Warning Display Module – This module
display’s the following engine failures:
D. Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this
lamp goes ON during normal operation of
the generator, stop the engine and fill the
battery with distilled water to the specified
level.
E. Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this
lamp goes ON during normal operation of
the generator, stop the engine and replace
the air filter.
7.
Pre-Heat Lamp – Indicates that the glow
plugs of the diesel engine are hot and the
engine is ready to be started.
8.
Pre-Heat Button – Press hold this button
until the pre-heat lamp is lit (ON).
9.
Throttle Handle - This handle controls the
speed of the engine (low or high).
A. Overheat Lamp – This lamp goes ON when
the cooling water temperature rises
abnormally. If the lamp goes ON during
normal operation of the generator, the
emergency shut-down device will stop the
engine automatically.
B. Low Oil Pressure Lamp – During normal
operation of the generator this lamp should
remain OFF. When the Auto-OFF/ResetManual 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.
C. Low Fuel Level Lamp – When this lamp
is ON, it is time to stop the engine and add
fuel. Remember to let the engine cool
before adding fuel.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 31
Table of Contents
DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
OUTPUT TERMINAL PANEL FAMILIARIZATION
The “Output Terminal Panel” is provided with the following:
" Three 240/139V output receptacles, 50 amp
" Two 120V input receptacles, 20 amp
" 3 Load Circuit Breakers 265V @65 amps
" 2 Load GFCI Circuit Breakers [email protected] 20amps
Connecting Load
Loads can be connected to the generator by the UNV Lugs or
the convienience receptacles. (See figure 13). Make sure to
read the operation manual before attempting to connect a load
to the generator.
Control Box
The “Control Box” is provided with the following:
" Main Circuit Breaker 400 amps
" Over-Current Relay
Output Terminal Panel
The Output Control Panel (See Figure 14) is located on the
right hand side (left from control panel) of the generator.
The UNV lugs are protected by a face plate cover that can
be secured in the close position by a pad lock. (See Figure
11).
FIGURE 11. Output Terminal Cover
120 Volt Recetacle
Two GFCI Duplex Nema 5-20R (120V, 20 Amp) recepacle is
provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
Pressing the reset button resets the receptacle after being
tripped. Pressing the "Test Button" (See Figure 12) in the
center of this receptacle will check the GFCI function. The
receptacle should be tested at least once a month.
FIGURE 13. Connecting Load
Circuit Breakers
To protect the generator from an overload, a 3-pole, 400 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.
Maximum Output
The entire load connected to the UNV Lugs, all four slots in the
duplex receptacles, and the must not exceed 132 kW in
standby or 120 kW in prime output.
Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
Control Panel (see figure 14). Place the voltmeter changeover switch to the U-W positon and the ammeter changeover switch to the U or W to read the output.
FIGURE 12. GFCI Test Button
PAGE 32 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
NOTE
Legs O and Ground are
considered Bonded Grounds.
FIGURE 14. Output Terminal Panel
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 33
Table of Contents
DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
Output Terminal Panel Available Voltages
A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and how you hookup
your hard wire connection to the generator. To obtain some
of the voltages listed, fine adjustment with the Voltage
Regulator on the control panel is necessarry. See the
table below (Table 8) for a list of available voltages the
generator is able to supply.
TABLE 8. VOLTAGES AVAILABLE
MODEL
DCA150SSKll
3 PHASE VOLTAGE
(SWITCHABLE)
208 VOLT
220 VOLT
240 VOLT
416 VOLT
440 VOLT
480 VOLT
SINGLE PHASE
(SWITCHABLE)
120 VOLT
127 VOLT
139 VOLT
240 VOLT
254 VOLT
277 VOLT
Voltage Selector Switch
The voltage selector switch is located above the UVWO
Hard Wire Hook-up Panel. It has been provided for ease of
voltage selection.
CAUTION :
NEVER switch Voltage Selector Switch
position while the engine is engaged.
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the Voltage Selector Switch,
press in the red button located on the Voltage Selector
Switch, and use a pad lock to hold it into this position.
Over Current Relay
An over current relay is connected to the circuit breaker.
In an over current situation, both the circuit breaker and
the over current relay may trip. If the circuit breaker can
not be reset, the reset button on the over current relay
must be pressed. The over current relay is located in the
control box.
Maximum Amps
The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed. (See Table 9)
Table 9. Maximum Amps
Model:
DCA150SSKll
Rated
Voltage
Maximum Amps
Single Phase
120 Volt
333.3 amps (4 wire)
Single Phase
240 Volt
166.7 amps (4 wire)
Three Phase
240 Volt
361 amps
Three Phase
480 Volt
180 amps
Receptacle Use
When the UVWO terminals are providing power, the
receptacle power available decrease. Do not exceed
receptacle power available listed on Table 10.
Table 10. R eceptacle U se
Pow er in U se
R eceptacle
P o w er
Available
240/480V
3-Phase
240/120V
Single Phase
or Tw ist
L o ck C S 6369
D uplex
N EMA
5-20R 120V
K VA
KW
KW
150
87
0
146
85.8
1.2
142
84.6
2.4
138
83.4
3.6
133
82.2
4.8
PAGE 34 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
How to read the output terminal guages.
The guages and knobs on the control panel DO NOT effect
the generator output in any fashion. They are there to
simply help the operator observe how much power is being
supplied produced at the UVWO legs.
When the voltage selector switch is in the 240/120V
position (see figure 15), place the AC Voltmeter Changeover switch to the W-U position and the AC ammeter
Change-over Switch to the U or W position to read the
output on the selected leg.
FIGURE 18. AC Ammeter
Change-over Switch
(Reading the U leg on the
output terminal panel)
FIGURE 19. ACAmmeter
(Amp reading on U lug)
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
FIGURE 15. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 16. AC Voltmeter
Change-over switch
(Reading the W-U leg on
the outputerminal panel)
FIGURE 17. AC Voltmeter
Guage
(Volt reading on W-U Lug)
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 35
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DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
240/120V Hard Wire Hookup
480/240V Hard Wire Hookup
The output terminal panel, when suppling single phase 120
volts, will provide three legs available with 333.3 amps each
on three different circuits. (See Figure 21 below.) The voltage
selector switch must be set at the single phase 240/120V
position. (See figure 20 below.)
The output terminal panel, when suppling single phase 240
volts, will provide one leg only with 166.7 amps available.
(See Figure 21 below.) The voltage selector switch must be
set at the single phase 240/120V position. (See figure 20
below.)
The output terminal panel, when suppling three phase 240
volts, will provide one circuit available at 361 amps with any
two wires plus the ground. (See Figure 23 below.) The voltage
selector switch must be set at the three phase 480/277V
position. (See figure 22 below.)
The output terminal panel, when suppling 3 phase 480 volts,
will provide one circuit available at 180 amps available with
all three wires plus ground. (See Figure 23 below.) The
voltage selector switch must be set at the three phase 480/
277V position. (See figure 22 below.)
FIGURE 20. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 22. Voltage Selector Switch 480/277V Three Phase
Position
FIGURE 21. Hard Wire Hook-up at 240/120V Position
FIGURE 23. Hard Wire Hook-up at 480/240V Position
PAGE 36 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
Voltage Selector Switch- 3 Phase 480/277V Position
The following are additional voltages available when the
voltage selector switch is in the 3 phase 480/277V
position. (See figure 24 below.)
Single Phase: 480V, 440V, or 416 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 24),
can offer SINGLE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
figure 27 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 25).
FIGURE 25. Voltage
Regulator Knob Located
on the Control Panel.
FIGURE 24. Voltage Selector Switch 480/277V Single Phase
Position
3 Phase, 480V, 440V, or 416 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 24),
can offer THREE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
figure 26 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 25).
FIGURE 26. Hard Wire Hook-up for Three Phase 480V, 440V,
or 416V
FIGURE 27. Hard Wire Hook-up for Single Phase 480V, 440V,
or 416V
Single Phase: 277V, 254V, or 240V
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 24),
can offer SINGLE PHASE power at 277V, 254V, or 240V.
After hooking up the hard wires to the lugs as shown in
figure 28 below, 277V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 254 volt will be
reached when the Voltage Regulator Knob is turned down,
and 240 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 25).
FIGURE 28. Hard Wire Hook-up for Single Phase 277V, 254V,
or 240V
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 37
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DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
Voltage Selector Switch- 3 Phase 240/139V Position
The following are additional voltages available when the
voltage selector switch is in the 3 phase 240/139V
position. (See Figure 29 below.)
Single Phase: 240V, 220V, or 208 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer SINGLE PHASE power at 240V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
figure 32 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).
FIGURE 30. Voltage
Regulator Knob located
on the control panel
FIGURE 29. Voltage Selector Switch 240/139V Three Phase
Position
3 Phase, 240V, 220V, or 208 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer THREE PHASE power at 240V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
figure 31 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).
FIGURE 31. Hard Wire Hook-up for Three Phase 240V, 220V,
or 208V
FIGURE 32. Hard Wire Hook-up for Single Phase 240V, 220V,
or 208V
Single Phase: 139V, 127V, or 120V
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer SINGLE PHASE power at 139V, 127V, or 120V.
After hooking up the hard wires to the lugs as shown in
figure 33 below, 139V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 127 volt will be
reached when the Voltage Regulator Knob is turned down,
and 120 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).
FIGURE 33. Hard Wire Hook-up for Single Phase 139V, 127V,
or 120V
PAGE 38 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — OUTPUT TERMINAL PANEL OVERVIEW
Voltage Selector Switch- Single Phase 240/120V
Position
The following are additional voltages available when the
voltage selector switch is in the single phase 240/120V
position. (See Figure 34 below.)
Single Phase: 120 Volt
The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 34), will offer SINGLE PHASE power at 120V. After
hooking up the hard wires to the lugs as shown in figure 37
below, use the Voltage Regulator Knob to fine tune to
120V. (See Figure 35).
FIGURE 35. Voltage
Regulator Knob located
on the control panel
FIGURE 34. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 37. Hard Wire Hook-up for Single Phase, 120 volt
Single Phase, 240 Volt
The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 34), will offer SINGLE PHASE power at 240V. After
hooking up the hard wires to the lugs as shown in figure 36
below, use the Voltage Regulator Knob to fine tune to
240V. (See Figure 35).
FIGURE 36. Hard Wire Hook-up for Single Phase 240 volt
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 39
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Outdoor Installation
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure that 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.
DCA-150SSKII — INSTALLATION
CAUTION :
An electric shock is apt to 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.
Generator Grounding
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, not
only to the engine parts, but also to the alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
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 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 9) 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.
DO NOT cover ventilation areas on the enclosure, covering
the ventilation grids will cause the engine to over heat.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
PAGE 40 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — INSTALLATION
Figure 38.
Typical Generator Grounding Application
CAUTION :
Always check Local, State, and Federal
laws before grounding generator set.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 41
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DCA-150SSKII — PRE-SETUP
General Inspection Prior to Operation
The DCA-150SSKII 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 Table 11 (cable selection guide) as a
guide for selecting proper cable size.
Circuit Breakers
To protect the generator from an overload, a 3-pole, 400 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.
Table 11. C able Selection (60 H z , Single Phase Operation)
Load In Watts
C urrent
At
in
At 120
240
Amperes Volts
Volts
Maximum Allow able C able Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
C AUTION: Equi pment damage can result from low voltage.
PAGE 42 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — 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 that the oil level is maintained
between the two notches (Figure 39) on the dipstick. See
Table 3 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 23,
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 39. Engine Oil Dipstick
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.
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.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
Table 12. Recommended Motor Oil
Temperature
R an g e
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
S A E 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
Below 5° C (-15°)
SAE 10W or SAE 10W-30
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 43
Table of Contents
DCA-150SSKII — 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
13. for engine, radiator, and reserve tank coolant capacities.
Make sure that the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Table 13. Coolant Capacity
Engine and Radiator
7.4 Gal. (28 Liters)
Reserve Tank
2 Quarts (11.9 Liters)
Operation in Freezing Weather
When operating in freezing weather, be certain that the proper
amount of antifreeze (Table 14) has been added.
Cleaning the Radiator
The radiator may overheat if the 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.
The fan belt tension is proper if the fan belt bends 7 to 10
mm (Figure 40) when depressed with the thumb as shown
below.
Figure 40. Fan Belt Tension
Day-to-day addition of coolant is done from the
Table 14. Anti-Freeze Operating Temperatures
Vol %
Anti-Freeze
Freezing Point
°C
°F
Boiling Point
°C
-24
-12
106
222
50
-37
-34
108
226
When the anti-freeze is mixed with
water, the anti-freeze mixing ratio
must be less than 50%.
Never place hands near the belts or fan
while the generator set is running.
°F
40
NOTE
CAUTION :
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 44 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — PRE-SETUP
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 41) 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.
Figure 41. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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. ALWAYS make sure that the Off/Manual/Auto switch is
in the "OFF" position when connecting the battery. If
the generator is equipped with an ignition switch, make
sure the ignition switch is in the "OFF" postion and the
key is removed.
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-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 45
Table of Contents
DCA-150SSKII — LOAD APPLICATION
CAUTION:
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.
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
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.
" When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of
up to the generating set’s rated output (kW) can be
used.
" When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output
(kW) multiplied by 0.6 can be used.
" When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
The power factor of this generator is 0.8. See Table 15.
below when connecting loads.
Table 15. Pow er Factor B y Load
Type Of Load
Si ngle-phase i nducti on
motors
Electri c heaters,
i ncandescent lamps
Pow er Factor
0.4 - 0.75
1.0
Fluorescent lamps, mecury
lamps
0.4 - 0.9
Electroni c devi ces,
communi cati on equi pment
1.0
C ommon power tools
0.8
Three Phase Load
When calculating the power requirements for 3-phase
power use the following equation:
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.
NOTE
If output (kVA) is not given
on the equipment nameplate, approximate
output may be determined by multiplying
voltage by amperage by
.
PAGE 46 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — 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
Before Starting
Engine
2. Once it is determined if commercial power is required,
connect the load to the UNV terminals as shown in
Figure 43. These terminals can be found on the output
terminal panel, see page 33, Figure 14. 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.
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 12 on page 43).
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
Figure 43. UNV Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 44).
CAUTION:
NEVER start the engine with the
main, GFCI or load circuit
breakers in the ON position.
1. Be sure to disconnect the electrical load and switch the
main, load and G.F.C.I. circuit breakers (Figure 42) to
the “OFF” position prior to starting the engine.
IVE
ST
PO
E
TIV
GA
E
N
RY
E
TT
BA
Figure 44. Battery Connections
Figure 42. Main, GFCI and
Load Circuit Breakers
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 47
Table of Contents
DCA-150SSKII — GENERATOR START-UP PROCEDURE (MANUAL)
4. Close all engine enclosure doors (Figure 45).
7. After engine starts, verify that the "Engine Running"
status LED (Figure 49) on the Microprocessor Engine
Control Module (MPEC) display is "ON" (lit).
Figure 45. Engine Enclosure Doors
5. When starting the generator in COLD weather conditions,
press and hold the engine preheat button (Figure 46)
until the pre-heat lamp (Figure 47) is lit (ON).
Figure 49. MPEC Engine Running Status LED
8. If the unit has an ignition switch(Figure 50), turn the
key to the right, until the engine starts. Then
release the key to 'Run'.
Figure 46. Engine Pre-Heat Button
Figure 50. Ignition Switch (Run)
Figure 47. Engine Pre-Heat Lamp
9. Pull and turn the engine throttle lever (Figure 51) to
increase the engine speed to high.
6. Place the Off/Manual/Auto switch (Figure 48) in the
MANUAL position (down). Observe that the engine begins
to crank.
Figure 51. Engine Throttle Lever (High)
10. If the generator is equipped without the engine
throttle lever, set the idle control switch to the "ON"
position. (See figure 52)
Figure 48. Off/Manual/Auto Switch (Manual)
Figure 52. Idle Control (ON)
PAGE 48 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
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DCA-150SSKII — GENERATOR START-UP PROCEDURE (MANUAL)
11. The generator's frequency meter (Figure 53) displays
the 60 cycle output frequency in HERTZ.
14. The engine oil pressure gauge (Figure 57) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure should be
approximately 25 psi.
Figure 53. Frequency Meter (Hz)
12. The generator's voltage meter (Figure 54) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 55) to increase or
decrease the desired voltage.
Figure 57. Oil Pressure Gauge
15. The coolant temperature gauge (Figure 58) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
105 and 215 degrees fahrenheit (Green Zone).
WATER
Figure 54. Voltage Meter (Volts)
TEMP
Figure 58. Coolant Temperature Gauge
16. The tachometer (Figure 59) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed should be approximately
1800 RPM’s.
Figure 55. Voltage Adjust Control Knob
13. The ammeter (Figure 56) 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.
20
40
0
Figure 59. Engine Tachometer
60
75
A
Figure 56. Ammeter (No Load)
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 49
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DCA-150SSKII — GENERATOR START-UP PROCEDURE (AUTO)
17. After the engine has been running for a few minutes,
look at the status LED’S on the "MPEC" display (Figure
9) and check it for any abnormal conditions. If any
abnormal conditions exist, shut down the engine and
take corrective action to solve the problem.
18. 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 60).
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.
Starting the generator in the "AUTO" mode is similar to
starting the generator in the "MANUAL" mode, with a few
exceptions.
CAUTION:
Figure 60. Main and GFCI Circuit Breakers
19. Look at the generator's ammeter (Figure 61) 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.
20
40
0
60
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.
If the generator is equipped with an MPEC, when starting
generator in Auto mode use the "Manual Start-up" procedure
except where noted (see below).
75
A
Figure 61. Ammeter (Load)
1. Perform steps 1 through 6 (page 47-48) as outlined in
the manual starting procedure.
2. Place the Off/Manual/Auto switch (Figure 62) in the
AUTO position (up). Observe that the engine begins to
crank.
20. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 62. Off/Manual/Auto Switch (Manual)
3. Continue to follow the steps outline in the manual startup procedure (start at step 9, page 48).
PAGE 50 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — 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"
6. Verify that the "Engine Running" status LED (Figure
66) on the Microprocessor Engine Control Module
(MPEC) display is "OFF" (not lit).
2. Turn the Engine Throttle Handle (Figure 63)to the left and
push in to set the speed to 'low'.
Figure 66. MPEC Engine Running
Status LED (OFF)
Figure 63. Engine Throttle Lever (low)
3. If the generator is equipped with an idle control switch, set
the switch to "OFF" positon. (Figure 64)
7. If the generator is equipped with an ignition switch, (Figure
67) turn the key to the left to the "OFF" positionturn off
the engine.
Figure 67. Off/Manual Auto Switch (OFF)
Figure 64. Idle Control Switch (OFF)
4. Let the engine cool by running it for 3-5 minutes with no
load applied.
8. Remove the load from the UNVO terminal strip (Figure 14 page 33).
5. Place the Off/Manual/Auto Switch (Figure 65) in the "OFF/
RESET" position.
Figure 65. Off/Manual Auto Switch (OFF)
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 51
Table of Contents
DCA-150SSKII — 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.
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.
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 39 on page 43.
Generator Storage
For storage of the generator for over 30 days, the following
is required:
" Drain the fuel tank completely.
" Run the engine until the fuel completely consumed.
" Completely drain the oil from the crankcase and refill
with fresh oil.
" Stop the engine at the compression point.
" Clean all external parts of the generator with a cloth.
" Cover the generating set and store in a clean, dry place.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.
To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.
Service Daily
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
PAGE 52 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — MAINTENANCE
TAB LE 16.
IN SPEC TION / MAIN TEN AN C E
ENGINE
GENERATOR
10 Hrs
D AILY
C heck Engi ne Flui d Levels
X
C heck Ai r C leaner
X
C heck Battery Aci d Level
X
C heck Fan Belt C ondi ti on
X
C heck for Leaks
X
C heck for Looseni ng of Parts
X
250 Hrs
Replace Engi ne Oi l and Fi lter *1
X
C lean Ai r Fi lter
X
D rai n Bottom of Fuel Tank
X
C lean Uni t, Insi de and Outsi de
X
500 Hrs
C hange Fuel Fi lter *2
X
C lean Radi ator and C heck C oolant
Protecti on Level
X
1000 Hrs
Replace Ai r Fi lter Element
X
C hange C orrosi on Resi stor
X
C heck all Hoses and C lamps
X
C lean Insi de of Fuel Tank
X
Measure Insulati on Resi stance Over
3M ohms
X
*1 Replace engi ne oi l anf fi lter at 100 hours, fi rst ti me only.
*2 Replace fuel fi lter at 250 Hours, fi rst ti me only.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 53
Table of Contents
DCA-150SSKII — 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 17). If
the problem cannot be remedied, consult our company's
business office or service plant.
TABLE 17. ENGINE TROUBLESHOOTING
SYMPTOM
Engine does not start.
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Bleed system.
Water in the fuel system?
Remove water from fuel tank.
Fuel pipe clogged?
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity
of fuel or engine oil at low
temperature?
Use the specified fuel or engine oil.
Fuel with low cetane
number?
Use the specified fuel.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Incorrect injection timing?
Adjust.
Fuel cam shaft worn?
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump
malfunctioning?
Repair or replace.
Seizure of crankshaft,
camshaft, piston, cylinder
liner or bearing?
Repair or replace.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Replace.
Excessive valve clearance?
Adjust.
Starter malfunctioning?
Repair or replace.
Wiring disconnected?
Connect wiring.
Starter does not run.
PAGE 54 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TROUBLESHOOTING (ENGINE)
TABLE 17. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Engine revolution is not
smooth.
Either white or blue exhaust
gas is observed.
Either black or dark gray
exhaust gas is observed.
Deficient output.
POSSIBLE PROBLEM
SOLUTION
Fuel filter clogged or dirty?
Clean or change.
Air cleaner clogged?
Clean or change.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Injection pump
malfunctioning?
Repair or replace.
Incorrect nozzle opening
pressure?
Adjust.
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe
clogged?
Clean.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn
or stuck?
Repair or replace.
Incorrect injection timing?
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving parts
seem to be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 55
Table of Contents
DCA-150SSKII — 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 for
diagnosis based on the Engine and Radiator Troubleshooting
(Table 18) and the MPEC Troubleshooting (Table 19). If the
problem cannot be remedied, consult our company's
business office or service plant.
TABLE 18. ENGINE & GENERATOR TROUBLESHOOTING
SYMPTOM
Engine fails to start and
starter does not rotated.
Engine fails to start and
starter rotates.
POSSIBLE PROBLEM
SOLUTION
Dead battery?
Replace battery.
Defective starter switch?
Replace switch.
Fuse F5 burned out?
Replace fuse.
Broken pre-heat circuit?
Check pre-heat circuit.
No fuel?
Add fuel.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Engine starts and remains at
Clogged air cleaner?
low speed.
Disconnected wiring?
Engine speed rises and no
volteage is present n AC
power source.
Engine speed rises and AC
power voltage is too low or
cannot be used.
Clean or replace.
Check and repair wiring.
No voltage present in AC
power source?
Replace rectifier (RE1).
Defective rotor?
Replace rotor.
Defective voltmeter?
Replace voltmeter.
Disconnected wiring?
Check and repair wiring.
Layer short-circuit in armature
winding?
Replace armature.
Defective circuit breaker
(protector)?
Replace circuit breaker (protector).
Layer short-circuit, broken
wires in armature winding?
Repair or replace armature.
Defective engine regulator?
Engine speed rises and
battery discharges too soon. Defective wiring?
Engine speed rises and
engine seems overloaded.
Clean or replace.
Replace regulator.
Repair or replace wiring.
Defective alternator?
Repair or replace alternator.
Damaged alternator bearing?
Replace alternator bearings.
PAGE 56 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — TROUBLESHOOTING (MPEC)
TAB LE 19. MPEC TR OU B LESH OOTIN G
Sympton
Low oi l pressure
li ght i s on.
Low coolant level
li ght i s on.
Hi gh coolant
temperture li ght i s
on.
Overcrank li ght i s
on.
Overspeed li ght i s
on.
Loss of MPU
li ght(s) or on.
Possible C ause
Solution
Low oi l level?
Fi ll oi l level.
Oi l pressure sendi ng uni t fai lure?
Replace oi l pressure sendi ng uni t.
Ti me delay malfunti on i n MPEC ?
Refer to dealer.
Wi re shorted?
Inspect/repai r wi re.
Low coolant level?
Fi ll coolant level.
Sendi ng uni t fai lure?
Replace sendi ng uni t.
Low battery voltage?
Replace/charge battery.
Fan belt tensi on i ncorrect?
Ti ghten/replace fan belt.
Ai r flow i s not ci rculati on through
radi ator?
C lean/repai r radi ator gri ll.
D oors open?
C lose doors.
Exhaust leaki ng?
Replace/repai r gaskets or faulty part.
Generator bei ng overloaded?
C heck/reduce load.
Thermostat fai lure?
Replace thermostat.
Ai r i ntake blocked?
C lear all ai r i ntakes.
Temperature swi tch fai lure?
Replace temperature swi tch.
No or low Fuel?
Fi ll fuel level.
MPEC needs to be cali brated?
Refer to dealer.
RPM engi ne speed too hi gh?
Adjust RPM.
Governor actuator needs to be adjusted?
Adjust governor actuator.
Governor controller needs to be
adjusted?
Adjust governor controller.
MPEC needs to be cali brated?
Refer to dealer.
Magneti c pi ck up out of adjustment?
Adjust magneti c pi ck up.
Magneti c pi ck up di rty?
C lean magneti c pi ck up.
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 57
Table of Contents
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 58 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII — SUGGESTED SPARE PARTS
DCA-150SSKII W/KOMATSU S6D108E-2 ENGINE
1 to 5 Units
Qty.
P/N
Description
1 ......... 0601807346 ......... CIRCUIT BREAKER
1 ......... 0601840073 ......... RHEOSTAT (VOLTAGE REGULAR)
1 ......... 0601840121 ......... KNOB FOR RHEOSTAT
2 ......... 0601812598 ......... RECEPTACLE 530 EM
1 ......... 0601812565 ......... RECTIFIER
3 ......... 0602041147 ......... OIL FILTER CARTRIDGE
1 ......... 0810105004 ......... FUEL TANK CAP
3 ......... 0602042146 ......... FUEL FILTER CARTDIDGE
3 ......... 0602046338 ......... ELEMENT, AIR INNER
1 ......... 6008155390 ......... STARTER SWITCH
3 ......... 615 ...................... KEY, IGNITION
1 ......... 0602123087 ......... WATER TEMPERATURE GAUGE
1 ......... 0602122037 ......... OIL PRESSURE GAUGE
1 ......... 0602122251 ......... OIL SHUT-DOWN SENDING UNIT
1 ......... 0602123250 ......... WATER TEMPERATURE SENDING UNIT
3 ......... 0601822034 ......... RECEPTACLE, CS 6369 250V, 50 AMPS
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 59
Table of Contents
DCA-150SSKII— GENERATOR ASSY.
GENERATOR ASSY.
PAGE 60 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Generator
Table of Contents
DCA-150SSKII— GENERATOR ASSY.
GENERATOR ASSY.
Full View
NO.
1
1-1*
1-2*
1-3*
1-4*
1-5*
1-6*
1-7*
1-8*
1-9*
1-10*
1-11*
1-12*
1-13*
1-14*
1-15*
1-16*
1-17*
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
PART NO.
8151000312
8131070013
012010030
030210250
8131611004
8131015003
0012112035
0042612000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906312
8151340213
0845041804
8131315102
8101350013
0012110060
0042610000
031110160
0010112035
0040012000
031112230
8131310114
8131312214
8101331003
0105050616
8101333003
0010106030
0040006000
952404470
012010030
030210250
8131332003
0605000063
0030016000
0040016000
PART NAME
QTY.
REMARKS
ROTOR ASSY ................................ 1 .......... INCLUDE ITEMS W/*
FIELD ASSY
1
FAN
1
HEX HEAD BOLT ......................... 12 .......... REPLACES 0012110030
LOCK WASHER ............................ 12 .......... REPLACES 0042510000
COUPLING DISK
8
BALANCING PLATE
1
HEX HEAD BOLT
10
LOCK WASHER
10
SET PLATE RECTIFIER
1
RECTIFIER .................................... 2 .......... PT3610
SURGE ABSORBER ...................... 1 .......... ERZ -M14JK621A
INSULATOR WASHER
1
INSULATOR WASHER
1
HEX HEAD BOLT
4
LOCK WASHER
4
BALANCING WEIGHT KIT
1
BEARING
1
STATOR ASSY
1
GROMMET
2
END BRACKET
1
FIELD ASSY, EXCITER
1
HEX HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER ............................. 4 .......... REPLACES 0041210000
HEX HEAD BOLT
6
LOCK WASHER
6
PLAIN WASHER ............................. 6 .......... REPLACES 0041212000
COVER, BEARING
1
GASKET, BEARING
1
COVER, END BRACKET
1
HEX HEAD BOLT ......................... 10 .......... REPLACES 0017106012
COVER, END BRACKET
1
HEX HEAD BOLT
2
LOCK WASHER
2
PLAIN WASHER ............................. 2 .......... REPLACES 0041206000
HEX HEAD BOLT ......................... 12 .......... REPLACES 0012110030
LOCK WASHER ............................ 12 .......... REPLACES 0042510000
COVER, FAN
1
RUBBER SUSPENSION
2
HEX NUT
4
LOCK WASHER
4
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 61
Table of Contents
DCA-150SSKII — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 62 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Control Box
Table of Contents
DCA-150SSKII — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
Full View
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PART NO.
C0214001202
0601801148
0027104010
0601820851
0027104016
0601807346
0021006040
0440006000
952404470
0601820671
0017105016
6008151252
0017106016
0601823860
0027104010
0601823706
0027104010
0601823861
0027104010
6008152970
0017106016
0601824542
0227103010
0602201911
0017104016
M3923100014
8151839504
8151839714
0021304020
0021306020
0021306020
011008020
020108060
PART NAME
QTY. REMARKS
CONTROL BOX
1
CURRENT TRANSFORMER ........ 2 ........ CT-3.5MR300/SA
MACHINE SCREW
4
OVER CURRENT RELAY ............. 1 ........ TH-K20
MACHINE SCREW
2
CIRCUIT BREAKER ..................... 1 ........ XE400NS 400A
MACHINE SCREW
4
LOCK WASHER
4
PLAIN WASHER ........................... 4 ........ REPLACES 0041206000
AUTO. VOLTAGE REGULATOR ..... 1 ........ NTA-5A-2T
HEX HEAD BOLT
4
EMERGENGY RELAY ................. 1 ........ REPLACES 0602200446
HEX HEAD BOLT
4
RELAY UNIT ................................ 2 ........ MSA9013
MACHINE SCREW
4
RELAY .......................................... 1 ........ HE1A DC24V
MACHINE SCREW
2
STOP UNIT .................................. 1 ........ MSA9014
MACHINE SCREW
2
GLOW RELAY .............................. 1 ........ REPLACES 0602201227
HEX HEAD BOLT
2
RELAY .......................................... 1 ........ HH62S DC24V
MACHINE SCREW
2
UNIT, BATTERY SENSOR ........... 1 ........ C7038A-00-00
MACHINE SCREW
1
SELECTOR SWITCH ................... 1 ........ VY200/S1; REPLACES 8150153114
SET PLATE, SELEC. SWITCH 1
BRACKET, SELECTOR SWITCH 1
MACHINE SCREW
4
MACHINE SCREW
4
MACHINE SCREW
4
HEX HEAD BOLT ......................... 2 ........ REPLACES 0017108020
HEX NUT ...................................... 2 ........ REPLACES 0207008000
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 63
Table of Contents
DCA-150SSKII— CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 64 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Control Box
Table of Contents
DCA-150SSKII— CONTROL BOX ASSY.
CONTROL BOX ASSY. (CONT.)
NO.
31
32
33
34
35
36
37
38
39
40
41
Full View
42
43
44
45
46
47
48
49
50
51
52
PART NO.
C0224001403
0605011211
0601800487
0601808901
0601801040
0601800298
0601801041
0601810072
0601810261
0601840073
0601840121
0601810161
0601810214
0030004000
0601830710
C9221100004
0040008000
031108160
0080100007
3871824004
952404470
505015300
C0214500104
011008020
8361827504
011008020
011008020
PART NAME
QTY.
REMARKS
CONTROL PANEL
1
PIN
2
FREQUENCY METER ............................... 1 ............ TRC- 65CF 220V 45 ~65HZ
AC AMMETER ........................................... 1 ............ TRS- 65C0 ~300A0 ~600A
CHANGE.-OVER SWITCH., AMMETER .... 1 ............ SL- 2AS
AC VOLTMETER ........................................ 1 ............ TRR - 65C0 ~600V
CHANGE.- OVER SWITCH., VOLTMETER.1 ............ SL - 2VS
PILOT LAMP .............................................. 1 ............ LP - 132DC 220V
BULB .......................................................... 1 ............ CT - 13W
RHEOSTAT (VOLTAGE REGULATOR) ........ 1 ............ RA20A2SE102BJ 2W 1K OHM
KNOB
1
PANEL LIGHT ............................................. 1 ............ V325070
BULB
1
HEX NUT .................................................... 2 ............ REPLACES 0207004000
SWITCH, PANEL LIGHT
1
HEX HEAD BOLT
2
LOCK WASHER
2
PLAIN WASHER ......................................... 2 ............ REPLACES 0041208000
SNAP RING
2
STOPPER, CONTROL PANEL
1
PLAIN WASHER ......................................... 1 ............ REPLACES 0041206000
SNAP PIN .................................................. 1 ............ REPLACES 0605010502
COVER, CONTROL BOX
1
HEX HEAD BOLT ....................................... 8 ............ REPLACES 0017108020
PANEL, CONTROL BOX
1
HEX HEAD BOLT ....................................... 8 ............ REPLACES 0017108020
HEX HEAD BOLT ....................................... 4 ............ REPLACES 0017108020
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 65
Table of Contents
DCA-150SSKII— ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 66 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Engine and Radiator
Table of Contents
DCA-150SSKII— ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
1
PART NO.
C0924200084
1-1*
1-2*
1-3*
1-4*
6001816740
6136515121
6003118293
6004111191
1-5*
2
3
4
5
6
7
8
9
10
11
Full View 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
0602040678
6151619350
6151619340
00100120605
0030012000
031112230
C0311100004
0017110025
6221619320
6221619330
0726020971
0728100909
0728100809
0728101029
0728100197
0605000060
0030012000
0040012000
C9101000104
0802024004
0805008004
0802025104
C0321200004
C0321300004
011208025
0130008000
0134308100
0603325017
0602022294
0265800850
PART NAME
QTY. REMARKS
ENGINE .......................................... 1 ...... KOMATSU S6D 108E - 2
INCLUDE ITEMS W/*
ELEMENT, AIR CLEANER ............. 1 ....... REPLACES 0602046338
CARTRIDGE, OIL FILTER ............. 1 ....... REPLACES 0602041147
CARTRIDGE, FUEL FILTER .......... 1 ....... REPLACES 0602042146
CARTRIDGE., CORROSION
RESISTOR ..................................... 1 ....... REPLACES 0602045141
DUST SENSOR .............................. 1 ....... REX01 - 8126
RADIATOR ...................................... 1 ....... REPLACES 0602011866
RUBBER SHEET ............................ 2 ....... REPLACES 0605000073
HEX HEAD BOLT
4
HEX NUT
8
PLAIN WASHER ............................. 8 ....... REPLACES 0041212000
BRACKET, RADIATOR
2
HEX HEAD BOLT
6
RADIATOR HOSE ........................... 1 ....... REPLACES 0602014543
RADIATOR HOSE ........................... 1 ....... REPLACES 0602014425
RADIATOR HOSE ........................... 1 ....... REPLACES 0602014544
HOSE BAND .................................. 1 ....... REPLACES 0602014056
HOSE BAND .................................. 2 ....... REPLACES 0602014067
HOSE BAND .................................. 1 ....... REPLACES 0602014350
HOSE BAND .................................. 2 ....... REPLACES 0602014058
RUBBER SUSPENSION
2
HEX NUT
4
LOCK WASHER
4
DRAIN JOINT
1
PACKING, OIL PAN SIDE
1
PACKING
1
JOINT BOLT
1
DRAIN JOINT
1
DRAIN PLUG
1
HEX HEAD BOLT .......................... 2 ........ REPLACES 0017108025
ELBOW JOINT, 3/4
1
LONG NIPPLE
1
VALVE ............................................1 ........ BBS22020
HOSE JOINT
1
DRAIN HOSE
1
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 67
Table of Contents
DCA-150SSKII— ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 68 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
DCA-150SSKII— ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. (CONT)
NO.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
PART NO.
0605515074
08020810030
0802010900
8302082103
0021108020
020108060
0199601200
0193601200
0605515013
0193600450
0193600800
0268200900
0605515132
8302256104
8152256104
012210020
PART NAME
QTY. REMARKS
HOSE BAND
2
RESERVE TANK ........................... 1 ........ REPLACES 0802081003
CAP, RESERVE TANK .................. 1 ........ REPLACES 0602010900
BRACKET, RESERVE TANK
1
MACHINE SCREW
2
HEX NUT ....................................... 2 ........ REPLACES 0207008000
HOSE
1
HOSE
1
HOSE BAND
3
HOSE
1
HOSE
1
HOSE
1
HOSE BAND
2
CLAMPER ROD
1
CLAMPER ROD
1
HEX HEAD BOLT ........................... 3 ...... REPLACES 0017110020
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 69
Table of Contents
DCA-150SSKII — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 70 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
Engine Operating Panel
DCA-150SSKII — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
1
2
3
4
Full View
4-1*
4-2*
4-3*
4-4*
4-5*
4-6*
4-7*
5
6
7
8
9
10
11
12
13
14
15
16
16-1#
17
18
19
20
21
22
23
24
25
26
PART NO.
C0352100803
0017106016
0207006000
0602120558
0602120701
0602129032
0602120069
0602122037
0602123087
0602121060
0602115031
0602129031
0021806020
0021806050
0602120129
0602122251
0602123250
8132142004
0601840190
0036003000
7452140504
0030008000
0605010503
6008155390
0000000615
6008152371
C0355300114
0602180106
0030004000
0207006000
952404470
C0355200204
0017112025
C0484000303
0017110025
0207010000
PART NAME
QTY. REMARKS
OPERATING PANEL
1
HEX HEAD BOLT
4
HEX NUT
1
METER PANEL ASS’Y ................... 1 ...... 1573708760; INCLUDE ITEM W/*
WIRING HARNESS
1
METER PANEL .............................. 1 ...... 0577764130
TACHOMETER ............................... 1 ...... 1005694600
OIL PRESSURE GAUGE ............... 1 ...... 1005760430
WATER TEMP. GAUGE .................. 1 ...... 1005752740
CHARGING AMMETER ................. 1 ...... 1005730330
INDICATOR ASS’Y ......................... 1 ...... 0559004040
MACHINE SCREW
2
MACHINE SCREW
2
MACHINE SCREW
2
CABLE, TACHOMETER ................. 1 ...... 0578909990
UNIT, OIL PRESSURE ................... 1 ...... 0716000760
UNIT, WATER TEMPERATURE ...... 1 ...... 0715000331
SLIDE LEVER
1
KNOB ............................................. 1 ...... REPLACES 0805012904
HEX NUT
1
BRACKET
1
HEX NUT
2
SNAP PIN
1
STARTER SWITCH ........................ 1 ...... REPLACES 0602100049
INCLUDE ITEM W/#
KEY, STARTER SWITCH
PREHEATLAMP ............................. 1 ...... REPLACES 0602102047
GOVERNOR ROD
1
BALL JOINT
2
HEX NUT
2
HEX NUT
2
PLAIN WASHER ............................. 2 ...... REPLACES 0041206000
ROD GUIDE
1
HEX HEAD BOLT
2
SUPPORT LEG
1
HEX HEAD BOLT
4
HEX NUT
4
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 71
Table of Contents
DCA-150SSKII — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 72 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Table of Contents
Engine Operating Panel
DCA-150SSKII — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.(CONT)
NO.
27
28
29
30
31
32
33
34
35
36
37
Full View
38
39
40
41
42
43
44
45
46
47
47-1
48
49
50
51
52
53
PART NO.
8131860303
0801830304
0801830804
0039316000
0040016000
0041416000
011208035
8131865704
0605010051
0027103010
0027103016
0207003000
0017106016
0845032104
0845032004
011008020
0601812597
0601811034
0021304015
0030004000
031104080
06018053136
0601805840
8131817103
0223300200
011206020
8131865303
012212045
031112230
0805009804
0030012000
PART NAME
QTY. REMARKS
SET BOARD, OUTPUT TERM.
1
OUTPUT TERMINAL
5
HEX HEAD BOLT
5
HEX NUT
10
LOCK WASHER
15
PLAIN WASHER
20
HEX HEAD BOLT ............................ 5 .............REPLACES 0017108035
COVER OUTPUT TERMINAL
1
HINGE
2
MACHINE SCREW
6
MACHINE SCREW
6
HEX NUT
6
HEX HEAD BOLT
2
RUBBER COVER
1
SET FRAME RUBBER COVER
1
HEX HEAD BOLT ............................ 4 .............REPLACES 0017108020
RECEPTACLE ................................. 2 .............530EM; REPLACES 0601812598
RECEPTACLE ................................. 3 .............CS6369; REPLACES 0601812565
MACHINE SCREW ........................ 10 .............REPLACES 0027104015
HEX NUT
10
PLAIN WASHER ............................ 10 .............REPLACES 0041204000
CIRCUIT BREAKER ........................ 2 .............KM-51265V20A
CIRCUIT BREAKER ........................ 3 .............KM-52265V50A
BRACKET CIRCUIT BREAKER
1
RUBBER CUSHION
1
HEX HEAD BOLT ............................ 2 .............REPLACES 0017106020
COVER
1
HEX HEAD BOLT ............................ 2 .............REPLACES 0010012045
PLAIN WASHER .............................. 2 .............REPLACES 0041212000
RUBBER WASHER
2
HEX NUT
2
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 73
Table of Contents
DCA-150SSKII — BATTERY ASSY.
BATTERY ASSY.
PAGE 74 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Battery
Table of Contents
DCA-150SSKII — BATTERY ASSY.
BATTERY ASSY.
Full View
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART NO.
0168511551
0805000804
0805000904
0805002904
0037808000
0040008000
0041208000
0602220203
C0347500004
8302265304
8302265504
C0347200104
012010030
020310080
012212025
0040012000
031112230
0040512000
0845040414
0845041304
PART NAME
QTY. REMARKS
BATTERY ....................................... 2 ...... 115F51
BATTERY SHEET
2
BATTERY BAND
2
BATTERY BOLT
4
WING NUT
4
LOCK WASHER
4
PLAIN WASHER ............................. 4 ...... REPLACES 0041208000
BATTERY SENSOR
1
BATTERY CABLE
1
BATTERY CABLE
1
BATTERY CABLE
1
EARTH CABLE
1
HEX HEAD BOLT ........................... 4 ...... REPLACES 0010010030
HEX NUT ........................................ 4 ...... REPLACES 0030010000
HEX HEAD BOLT ........................... 1 ...... REPLACES 0010012025
LOCK WASHER
1
PLAIN WASHER ............................. 1 ...... REPLACES 0041212000
TOOTHED WASHER
1
TERMINAL CAP +
2
TERMINAL CAP 2
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 75
Table of Contents
DCA-150SSKII — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 76 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Muffler
Table of Contents
DCA-150SSKII — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
Full View
6
7
8
9
PART NO.
C0331100302
0017110025
C0334000003
6150115751
0012112045
0030012000
031112230
0010112050
0030012000
031112230
8252354004
C0334200104
011008020
PART NAME
QTY. REMARKS
MUFFLER
1
HEX HEAD BOLT
4
EXHAUST PIPE
1
GASKET ........................................ 1 ...... REPLACES 0602320142
HEX HEAD BOLT
4
HEX NUT
4
PLAIN WASHER ............................. 8 ...... REPLACES 0041212000
HEX HEAD BOLT
4
HEX NUT
4
PLAIN WASHER ............................. 8 ...... REPLACES 0041212000
COVER
2
SHEET
2
HEX HEAD BOLT ........................... 4 ...... REPLACES 0017108020
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 77
Table of Contents
DCA-150SSKII — FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 78 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Fuel Tank
Table of Contents
DCA-150SSKII — FUEL TANK ASSY.
FUEL TANK ASSY.
Full View
NO.
1
1-1*
*
1-2*
1-3*
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART NO.
C0364001003
0605505030
0810105400
0257700385
8135523304
0805003414
011008020
020108060
0222100320
0845047504
0802011104
0150000018
0191301100
0191301200
0191001750
0605515014
0605515013
0605503009
0802120604
0845039604
PART NAME
QTY. REMARKS
FUEL TANK .................................... 1 ...... INCLUDE ITEMS W/*
CAP FUEL TANK ............................ 1 ...... REPLACES 0605505005
KEY, CAP FUEL TANK
1
FUEL FILTER
1
HOSE, FUEL GAUGE
1
TANK BAND
2
PAD ,TANK BAND
4
HEX, HEAD BOLT .......................... 2 ...... REPLACES 0017108020
HEX, NUT ....................................... 2 ...... REPLACES 0037908000
TANK SHEET
4
DRAIN JOINT
1
PLUG
1
O RING
1
SUCTION HOSE
1
RETURN HOSE
1
RETURN HOSE
1
HOSE BAND
4
HOSE BAND
2
FUEL SENSOR
1
PACKING
1
RUBBER SEAL
1
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 79
Table of Contents
DCA-150SSKII — ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 80 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Enclosure
Table of Contents
DCA-150SSKII — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Full View
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NO.
C0414001602
C0414100004
011008020
C0424001502
C0494101203
0017110025
0845039703
011008020
8305125004
8305924104
0017108020
C0424200003
011008020
C0434000702
0010114050
020114110
030214350
031114260
0010120045
0030020000
0040020000
0041220000
C0444000802
8305940104
0017110025
8155155403
8155944104
011008020
8155156004
8155946104
011008020
8155118504
011008020
8155143703
C0444200413
B9114000102
0021806016
0030006016
8255146104
8255146204
0845050704
0207006000
8165157004
PART NAME
QTY. REMARKS
BASE
1
FLOOR PANEL
1
HEX, HEAD BOLT ......................... 10 ..... REPLACES 0017108020
FRONT FRAME
1
LINING
1
HEX, HEAD BOLT
8
FILLER BRACKET
1
HEX, HEAD BOLT ........................... 4 ..... REPLACES 0017108020
COVER, FRONT FRAME
1
LINING
1
HEX, HEAD BOLT
16
COVER, FRONT FRAME
1
HEX, HEAD BOLT ......................... 12 ..... REPLACES 0011708020
CENTER FRAME
1
HEX, HEAD BOLT
4
HEX, NUT ........................................ 4 ..... REPLACES 0030014000
LOCK WASHER ............................... 4 ..... REPLACES 0040014000
PLAIN WASHER .............................. 4 ..... REPLACES 0041214000
HEX, HEAD BOLT
4
HEX, NUT
4
LOCK WASHER
4
PLAIN WASHER
4
REAR FRAME
1
LINING
1
HEX, HEAD BOLT
4
COVER, REAR FRAME
1
LINING
1
HEX, HEAD BOLT ......................... 14 ..... REPLACES 0017108020
PANEL
1
LINING
1
HEX, HEAD BOLT ........................... 9 ..... REPLACES 0017108020
DUCT
4
HEX, HEAD BOLT ........................... 4 ..... REPLACES 0017108020
DOOR, REAR FRAME
1
DOOR, REAR FRAME
1
DOOR HANDLE
1
MACHINE SCREW
4
HEX, NUT
4
DOOR ROD
1
DOOR ROD
1
STAY
4
HEX, NUT
8
WINDOW PLATE
1
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 81
Table of Contents
DCA-150SSKII — ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 82 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Enclosure
Table of Contents
DCA-150SSKII — ENCLOSURE ASSY.
ENCLOSURE ASSY. (CONT)
NO.
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Full View
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
PART NO.
00377906000
B9114500104
0207006000
M9110100204
0845045004
M9110100304
0845045004
011008020
C0464100603
C0494500404
0845052203
C0464200203
C0494501804
011008020
C0454202102
0017108055
C0454002203
C0494403204
C0454002303
C0494403304
C0454002403
C0494403404
C0454002503
C0494403504
8135176104
8135976104
8135176004
8135976304
020108060
B9114000002
0825007362
0021806016
020106050
0845046904
0845045004
0845047004
0845045004
011008020
0601850057
0021008025
0845031504
B9511200003
0021106016
PART NAME
QTY. REMARKS
HEX. NUT
10
DOOR POCKET
1
HEX. NUT
4
HINGE ........................................... 2 ........ REPLACES 0845047104
WASHER
2
HINGE ........................................... 2 ........ REPLACES 0845047204
WASHER
2
HEX. HEAD BOLT ......................... 6 ........ REPLACES 0017108020
ROOF PANEL
1
LINING
1
FILLER COVER
1
ROOF PANEL
1
LINING
1
HEX. HEAD BOLT ....................... 36 ........ REPLACES 0017108020
SPLASHER PANEL
1
HEX. HEAD BOLT
4
SIDE DOOR
1
LINING
1
SIDE DOOR
1
LINING
1
SIDE DOOR
1
LINING
1
SIDE DOOR
1
LINING
1
DUCT
2
LINING
1
DUCT
1
LINING
1
HEX. NUT .................................... 21 ........ REPLACES 0207008000
DOOR HANDLE
4
DOOR HANDLE
3
MACHINE SCREW
28
HEX. NUT .................................... 28 ........ REPLACES 0030006000
HINGE
4
WASHER
4
HINGE
4
WASHER
4
HEX. HEAD BOLT ....................... 16 ........ REPLACES 0017108020
RUBBER CUSHION
10
MACHINE SCREW
10
CAP
12
EMBLEM
2
MACHINE SCREW
4
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 83
Table of Contents
DCA-150SSKII — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 84 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Rubber Seals
Table of Contents
DCA-150SSKII — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
Full View 5
6
7
8
9
10
PART NO.
0228901080
0228900840
0228900730
0228901080
0229201200
0228800650
0228801045
0229201190
0228100320
0228100540
PART NAME
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
QTY.
6
4
2
4
4
2
2
1
2
2
REMARKS
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 85
Table of Contents
DCA-150SSKII — NAME PLATE AND DECALS
NAME PLATE AND DECALS
PAGE 86 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Decals
Table of Contents
DCA-150SSKII — NAME PLATE AND DECALS
NAME PLATE ASSY.
Full View
NO.
1-1
PART NO.
0840624904
PART NAME
QTY.
REMARKS
DECAL; OPERATING PROCEDURE .................. 1 ............ S-3035
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
0800520100
0800520904
0800520814
0840624414
0840624504
0840624604
0840624704
0840624804
B9521100504
B9531100604
C0561103503
C251000004
CONTROL BOX GROUP
PLATE; ON - OFF ............................................... 1 ............ AT-202
PLATE; AMMETER CHG.- OVER SWITCH. ...... 1 ............ N-2438
PLATE; VOLTMETER CHG. - OVER SWITCH .... 1 ............ N-2439
DECAL; SELECTOR SWITCH ............................ 1 ............ S-3030A
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; CAUTION .............................................. 1 ............ B92110050
DECAL; WARNING ............................................. 1 ............ B93110060
DECAL; WHISPERWATT 150 ............................. 1 ............ C06110350
DECAL; SAFETY INSTRUCTIONS .................... 1 ............ C2510 0000
3-1
3-2
3-3
3-4
6360610304
6360620204
B9504000404
B9504100104
ENGINE RADIATOR GROUP
DECAL; WATER .................................................. 1 ............ S-1880
DECAL; OIL DRAIN PLUG ................................. 1 ............ S-1885
DECAL; WARNING ............................................. 2 ............ B90400040
DECAL; WARNING ............................................. 1 ............ B90410010
0840625004
0840625104
0840625204
0840625404
ENGINE OPERATING PANEL GROUP
DECAL; PREHEAT LAMP .................................. 1 ............ S-3036
DECAL; STARTER SWITCH .............................. 1 ............ S-3037
DECAL; SPEED CONTROL HANDLE ................ 1 ............ S-3038
DECAL; HANDLE POSITION ............................. 1 ............ S-3040
0840614104
0840619904
8110670323
0840627103
B1551001604
B9511100304
B9511100404
B9531100504
B9531100604
C0551001004
OUTPUT TERMINAL GROUP
DECAL; GROUND .............................................. 1 ............S-2635
DECAL; DANGER ............................................... 1 ............ S-2731
DECAL; RECEPTACLE & CIRCUIT BRKER. ..... 1 ............ S-3046B
DECAL; CABLE JOINING .................................. 1 ............ S 3245
DECAL; NOTE .................................................... 1 ............ B15100160
DECAL;WARNING .............................................. 1 ............B91110030
DECAL;WARNING .............................................. 1 ............B91110040
DECAL; WARNING ............................................. 1 ............ B93110050
DECAL; WARNING ............................................. 1 ............ B93110060
DECAL; NOTE .................................................... 1 ............ C05100100
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 87
Table of Contents
DCA-150SSKII — NAME PLATE AND DECALS
NAME PLATE AND DECALS
PAGE 88 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
Decals
Table of Contents
DCA-150SSKII — NAME PLATE AND DECALS
NAME PLATE ASSY.
NO.
PART NO.
6-1
6-2
0800689404
0800689504
PART NAME
QTY.
REMARKS
BATTERY GROUP
DECAL; + ........................................................... 1 ............S-2090
DECAL; - ............................................................ 1 ............ S-2091
7-1
B9504200004
MUFFLER GROUP
DECAL; WARNING ............................................. 1 ............ B 90420000
8-1
8-2
8-3
1320620904
6360620004
B9504500004
FUEL TANK GROUP
DECAL; DIESEL FUEL ....................................... 1 ............ S-1756
DECAL; FUEL DRAIN PLUG .............................. 1 ............ S-1883
DECAL; WARNING ............................................. 1 ............ B 90450000
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
9-10
9-11
1320610603
1320621504
0840625902
B9504000304
C0561100402
C0561101203
C0561100204
C0561100603
C0561102604
C0561101003
C0561100103
ENCLOSURE GROUP
DECAL; WATER- OIL .......................................... 1 ............ S-1760
DECAL; SUPPORT HOOK ................................. 2 ............ S-2257
DECAL; MQ ........................................................ 1 ............ S-3057
DECAL; CAUTION .............................................. 1 ............ B90400030
STRIPE
1
STRIPE
1
STRIPE
2
STRIPE
1
STRIPE
2
STRIPE
1
STRIPE
1
Full View
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 89
Table of Contents
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4.
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.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5.
Parts must be in new and resalable
condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.
6.
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.
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.
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.
c.
Any line item with an extended dealer
net price of less than $5.00.
d.
Special order items.
RETURNED GOODS POLICY
e.
Electrical components.
Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:
f.
Paint, chemicals, and lubricants.
LIMITATIONS OF SELLER’S LIABILITY
g.
Decals and paper products.
1.
h.
Items purchased in kits.
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.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
a.
b.
The list must be typed or computer
generated.
c.
The list must state the reason(s) for
the return.
d.
The list must reference the sales
order(s) or invoice(s) under which
the items were originally purchased.
e.
3.
The parts numbers and descriptions
must match the current parts price
list.
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.
7.
The sender will be notified of any material
received that is not acceptable.
8.
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.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
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 90 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)
NOTE PAGE
DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 91
PARTS AND OPERATION MANUAL
Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927
Manufactured for Multiquip Inc.
by
DENYO, MANUFACTURING, CO., USA
MULTIQUIP INC.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: 310-537-3927
E-MAIL: [email protected]
WWW: multiquip.com
Atlanta • Boise • Dallas • Houston • Newark
Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX
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