Multiquip DCA-220SSK User Manual

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PARTS AND OPERATION MANUAL

Table of Contents

PARTS AND OPERATION MANUAL

MQ POWER

DCA-220SSK

WHISPERWATT

GENERATOR

(Standard)

Up to S/N3696500 S/N3699150 to S/N3699619 S/N3699637 to S/N3703349 S/N3703364 to S/N3703853

S/N3703869~

(For serial numbers not listed, please refer to Sunbelt or GEER manuals)

Revision #3 (06/05/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 F AX: 310-537-3927 F AX: 310-638-8046 E-mail:mq@multiquip.com

SERVICE DEPARTMENT:

• www:multiquip.com

Table of Contents

PAGE 2 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

HERE'S HOW TO GET HELP

Table of Contents

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

SER VICE 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-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — 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 Safety Precaution .....................................10

Trailer Safety Guidelines.......................................11-17

T railer Wiring Diagram ...........................................18

Electrical Brake Troubleshooting...........................19

Hydraulic Brak e Troubleshooting...........................20

Operation and Safety Decals................................21-22

DCA 220 Specifications .......................................23

General Information ..............................................24-26

Major Components ...............................................27

Dimensions...........................................................28-29

Control Panel Descriptions ...................................30-31

Engine Operating P anel Descriptions ................... 32-33

Output T erminal Overview.....................................34-41

Installation ............................................................42-43

Pre Setup .............................................................44-47

Load Application ...................................................48

Generator Start-up Procedure (Manual)................49-52

Generator Start-up Procedure (Auto)....................53

Generator Shut-Down Procedure ..........................54

Maintenance .........................................................56-59

Generator Wiring Diagram .....................................60

Engine Wiring Diagrams ....................................... 62-63

Engine T roubleshooting .........................................64-65

Generator/Engine T roubleshooting ........................66

MPEC T roubleshooting .........................................67

Explanation of Code in Remarks Column .............68

Serial Numbers Pertaining to Unit ........................68

Suggested Spare Parts ........................................69

NOTE

DCA-220SSK GENERA TOR

Generator Assembly-Up to S/N1337562...............70-73

Generator Assembly-S/N1337563~ ......................74-77

Control Box and Panel Assembly-

Up to S/N1337562 ................................................78-81

Control Box and P anel (Optional)-

Up to S/N1337562 ................................................82-85

Control Panel Assemb ly-S/N1337563~.................86-87

Control Box Assembly-S/N1337563~ ...................88-91

Engine & Radiator Assembly-Up to S/N1337562..92-95 Engine & Radiator Assembly-

S/N1337563 to 3690734 .......................................96-99

Engine & Radiator Assembly-S/N3690735~ .........100-103

Engine Operating and Output Terminal Assembly-

Up to S/N1337562 ................................................104-109

Engine Operating Panel Assembly (Opt. Parts,

with Slow-Down)-Up to S/N1337562 .....................110-115

Engine Operating P anel Assembly-S/N1337563~ 116-119 Output T erminal Panel Assembly-

S/N1337563 to 3690734 .......................................120-121

Output T erminal Panel Assembly-S/N3690735~ ...122-123

Actuator-S/N3690735~ .........................................124-125

Battery Assembly ................................................. 126-127

Muffler Assembly ................................................. 128-129

Fuel Tank Assembly-Up to S/N1337562 ...............130-131

Fuel T ank Assembly-S/N1337563~.......................132-133

Enclosure Assembly-Up to S/N1337562 ..............134-139

Enclosure Assembly-S/N1337563~......................140-145

Rubber Seal Assembly-Up to S/N1337562........... 146-147

Rubber Seal Assembly-S/N1337563~ ..................148-149

Automatic Oil Feeder Assembly (Opt. Parts)-

Up to S/N1337562 ................................................150-151

Control Box Assembly Remote (Opt. Parts)-

Up to S/N1337562 ................................................152-153

Name Plate And Decals .......................................154-157

Specification and part number are subject to

Terms and Condition of Sale — Parts .................. 158

change without notice.

PAGE 4 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

PARTS ORDERING PROCEDURES

Table of Contents

■■

■ 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*

•

Tr uck 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 Additional Discount

1-9 items 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 an y other carrier. **Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

Now! Direct TOLL-FREE access

Extra Fax Discount for

Domestic USA Dealers

Only

UPS

Special

For faxed orders only

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE* Fax order discount and UPS special programs revised June 1, 1995

800/6-PARTS-7 • 800-672-7877

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 5

CAUTION:

Table of Contents

RULES FOR SAFE OPERATION

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-220SSK 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 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 burns.

■

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

CAUTION

■

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

hot

components can cause serious

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

■

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

■

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

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

Whenever necessar y, replace nameplate, operation and safety decals when they become difficult read.

■

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

PAGE 6 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

■

Always use extreme 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

or even death.

Topping-off to filler por t is dangerous, as it tends to spill fuel.

CAUTION

bodily harm

RULES FOR SAFE OPERATION

Table of Contents

CAUTION

■

NEVER touch output terminals dur ing operation. This is extremely dangerous. contact with the output terminals.

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.

Always stop the machine when

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

■

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.

engine is hot due to high pressure, 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 .

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.

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.

CAUTION

Never use damaged or worn cables when

connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 7

RULES FOR SAFE OPERATION

Table of Contents

Battery

CAUTION

The battery contains acids that can cause injury to the eyes and skin. To avoid ey e irritation, alwa ys wear safety glasses . Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

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

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur .

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

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

Always service air cleaner frequently to prevent carburetor malfunction.

Always disconnect the battery before performing service on the generator .

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

Always store equipment properly when not in use. Equipment should be stored in a clean, dry location out of the reach of children.

DO NOT lea ve the generator running in the manual mode unattended.

DO NOT allow unauthorized people to operate this equipment.

Always read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

Refer to the technical questions or information.

Komatsu Engine Owner's Man ual

for engine

3. Always keep the battery charged. If the battery is not charged a buildup of combustib le 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 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.

clothing or skin

, rinse skin or clothing

Loading and Unloading (Crane)

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

Always drain fuel prior to lifting.

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

NEVER lift the machine while the engine is running.

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

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

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

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

PAGE 8 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

RULES FOR SAFE OPERATION

Table of Contents

Transporting

■

Always shutdo wn engine before transporting.

■

Tighten fuel tank cap securely.

■

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

■

Alwa ys tie-down the generator during transportation by securing the generator .

■

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

Emergencies

■

Always know the location of the nearest

extinguisher

nearest telephone. Also know the phone numbers of the nearest

and

first aid kit

ambulance, doctor

. Know the location of the

and

fire department

fire

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

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

Keep the machinery in proper running condition. Fix damage to the machine immediately and always

replace broken parts. Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

DO NOT use plastic containers to dispose of hazardous waste.

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

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 9

DCA-220SSK — TOWING

Table of Contents

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

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

■

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

■

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

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS attach trailer's saf ety chain to bumper of towing vehicle.

■

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

■

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

■

Place

rolling,

■

Place prevent

■

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.

■

Av oid 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 tr ansporting.

chocked blocks

while parked.

support b locks

tipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

■

ALWAYS mak e sure the trailer is equipped with a "Safety Chain".

■

DO NOT transport generator with fuel in tank.

PAGE 10 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 1. Generator with Trailer

DCA-220SSK — TRAILER-SAFETY GUIDELINES

Table of Contents

CAUTION:

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

Explanation of Chart:

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

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

Brakes

Tires

Lug Nut T orquing

Suspension

Electrical

Brake T roubleshooting T ables

Use the following definitions reading Table 1.

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

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, h ydraulic-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 measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to fender.

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

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

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185, 205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (lay ers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

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

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

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 4 and Figure 5 or lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3). Please not that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

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

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

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

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 11

DCA-220SSK — TRAILER-SPECIFICATIONS

Table of Contents

snoitacificepS.1elbaT

LEDOM NOITACILPPA LEUF

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FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

TBS52-RLRT 52-ACDONONSBL0992"021"66.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

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521/58-RLRT ,001,58-ACD

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FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

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PAGE 12 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER-SPECIFICATIONS

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 13

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

Brakes

If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet. Listed below are some of the advantages that electric brakes have over hydraulic brakes:

Brake system can be manually adjusted to provide the

corrected braking capability for varying road and load conditions

Brake system can be modulated to provide more or less

braking force, thus easing the brake load on the towing vehicle

Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the tr ailer’s brakes are actuated

Brake system can provide an independent emergency

brake system

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

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

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

Electric Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

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

6. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

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

8. Repeat steps 1 through 6 on the remaining brakes.

PAGE 14 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

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 bra kes 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 require inspection and maintenance. Inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 15

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

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 in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in

the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold bef ore operation DO NO T bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear . Table 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Suspension

The leaf suspension springs and associated components (Figure 4) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately . T orqued suspension components as detailed in Table 3.

CAUTION:

AL WA YS w ear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

NOTE

Figure 4. Major Suspension Components

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Table of Contents

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-220SSK — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FI T ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAI N NUT

BOLT ASSEMBLY

05-XAM03-NIM

Lug Nut Tor que Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Star t 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.

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

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SBL-TF

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Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 17

DCA-220SSK — TRAILER-WIRING DIAGRAM

Table of Contents

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 19

DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING

Table of Contents

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PAGE 20 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK —OPERATION AND SAFETY DECALS

Table of Contents

Machine Safety Decals

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

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 21

DCA-220SSK —OPERATION AND SAFETY DECALS

Table of Contents

PAGE 22 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK SPECIFICATIONS

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 23

DCA-220SSK — GENERAL INFORMATION

Table of Contents

DCA-220SSK F AMILIARIZATION Generator

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

Engine Control Panel

The “Engine Control Panel” is provided with the f ollowing:

Tachometer

Water T emperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine W arning Lamp Module

Engine Speed Switch

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Generator Control Panel

The “Generator Control P anel” is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

V oltmeter Change-Ov er Switch

Panel Light

Panel Light Switch

Pilot Lamp

Microprocessor Engine Control Unit

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 600 amps

Over-Current Relay

High Idle Adjust Trimmer

generator

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 600 amps

Over-Current Relay

High Idle Adjust Trimmer

Open Delta Excitation System

The DCA-220SSK generator is equipped with the state of the art " 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 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 " according the demands of the required load.

Microprocessor Controlled Alarm System

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

Open-Delta

" excitation system. The open delta

Automatic V oltage Regulator

fixed ceiling

(A VR) is supplied

" and responds

Output T erminal Panel

The “Output T erminal P anel” is provided with the f ollowing:

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 265V@ 20amps

PAGE 24 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAL INFORMATION (OPTIONS)

Table of Contents

Engine The DCA-220SSK is powered by a 4 cycle, water cooled,

diesel

turbocharged K OMA TSU Model SA6D125E-2 This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 16 for engine specifications.

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

The basic controls and indicators for the DCA-220SSK generator are addressed on the following pages.

Electronic Governor System

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

Jacket Water Heater

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

engine.

CAUTION

Battery Charger

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

ALWAYS unplug the jacket water heater

before servicing.

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

NOTE: The jacket water heater can be

serviced if not functioning properly.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 25

DCA-220SSK — WATER SEP ARATOR FILTER (OPTIONAL)

Table of Contents

Water Separator Filter

The DCA-220SSK generator may be equipped with a “Water Fuel Separator". This unit is designed to prevent dirt, rust, algae, varnishes and water from entering the fuel system.

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

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

CAUTION

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

the OFF position.

Figure 6. Water Separator Filter

Collection Bowl W ater Draina ge

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

To drain the collection bowl perform the following:

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

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

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

PAGE 26 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — MAJOR COMPONENTS

Table of Contents

Figure 7. Major Components

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 27

DCA-220SSK — DIMENSIONS (T OP AND SIDE)

Table of Contents

PAGE 28 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 8a. Dimensions

DCA-220SSK — DIMENSIONS (FRONT AND REAR)

Table of Contents

Figure 8b. Dimensions

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 29

DCA-220SSK — CONTROL PANEL

Table of Contents

PAGE 30 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 9. Control Panel

DCA-220SSK — CONTROL PANEL

Table of Contents

The definitions below describe the controls and functions of the DCA-220SSK "

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 UVW 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.

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

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 activ ated, 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 10), that when lit, indicate that an engine malfunction (fault), has been detected. When a fault has been detected the MPEC will evaluate the fault and if the fault is major will shutdown the generator .

Control Panel

Figure 10. MPEC Module

" (Figure 9).

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the MPEC's " Over Crank Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the MPEC will shutdown the engine by initializing the "Over Speed Protection" mode.

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

A. Off/Manual/Auto Switch – This switch controls the

running of the generator. If this s witch is left in the "OFF" position, the generator will not run. When this s witch is set to the 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 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

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

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable . Typical programmable start settings is 3 cycles with a 10 second duration .This is considered a

E. Overspeed Shutdown – Indicates the engine is

running at an unsafe speed. This is considered a fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

manual

fault.

position, the generator will start

auto

position. In this position the

major

fault.

major

fault.

major

During engine for 10 seconds before disengaging.

cranking cycle

, The MPEC will attempt to crank the

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 31

DCA-220SSK — ENGINE OPERATING P ANEL

Table of Contents

PAGE 32 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 11. Engine Operating Panel

DCA-220SSK — ENGINE OPERATING P ANEL

Table of Contents

The definitions below describe the controls and functions of the DCA-220SSK "

1. Engine Speed Switch – This switch controls the constant speed of the engine.

2. Caution Lamp - This light indicates the generator is running.

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

4. 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.

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

A. Overheat Lamp – This lamp goes ON when

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

Engine Operating Panel

"(Figure 11).

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.

6. 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.

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

8. 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.

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

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 shutdown device will stop the engine automatically.

C. Low Fuel Level Lamp – When this lamp

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

D. Low Battery Fluid Lamp – This lamp goes

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

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

11. Starter Switch - This turns the generator on or off.

(The generator is not equipped with this feature if has MPEC (see Control Panel).

12. Battery Switch – This switch should be set to the ON position during normal operation. When the engine has been stop, place this switch in the OFF position. DO NO T turn this switch during normal operation, it could cause damage to the electrical equipment.

13. Air Cleaner Indicator - Indicates the air filter needs replacement.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 33

DCA-220SSK — OUTPUT TERMINAL PANEL OVERVIEW

Table of Contents

OUTPUT TERMINAL FAMILIARIZATION

The “Output T erminal P anel” is provided with the f ollowing:

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 600 amps

Over-Current Relay

Output T erminal Panel

The Output Control Panel (See Figure 16) is located on the right hand side (left from control panel) of the generator. The UVW lugs are protected by a face plate cover that can be secured in the close position by a pad lock. (See Figure

12).

Connecting Load

Loads can be connected to the generator by the UVW Lugs or the convenience receptacles. (See Figure 14). Make sure to read the operation manual before attempting to connect a load to the generator.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 600 amp ,

main

circuit breaker is provided to protect the UVW 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 have also been provided to protect the load side of the generator from overload. Make sure to switch breakers to the "OFF" position prior to starting the engine.

FIGURE 14. Connecting Load

load

circuit breakers

ALL

circuit

FIGURE 12. Output Terminal Cover

120 V olt Receptacle

Two GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle 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 13) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.

FIGURE 13. GFCI Test Button

PAGE 34 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Maximum Output

The entire load connected to the UVW Lugs, all four slots in the duplex receptacles, and the must not exceed 88 kW in standby or 80 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. Place the voltmeter change-over switch to the U-W position and the ammeter change-over switch to the U or W to read the output.

DCA-220SSK — OUTPUT TERMINAL P ANEL OVERVIEW

Table of Contents

FIGURE 15. Output Terminal Panel

NOTE

Legs O and Ground are considered Bonded Grounds.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 35

DCA-220SSK — OUTPUT TERMINAL P ANEL OVERVIEW

Table of Contents

Output T erminal Panel Available V olta ges

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

Maximum Amps

The following table show the maximum amps the entire generator can provide. Do not exceed the maximum amps

listed (See Table 9 below). 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 necessary. See the table below (Table 8) for a list of available voltages the generator is able to supply.

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TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

Voltage Selector Switch

The voltage selector switch is located above the UVWO Hard Wire Hookup Panel. It has been pro vided for ease of voltage selection.

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CA UTION :

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Voltage Selector Switch Loc king 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 (See Figure 17, page 37).

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.

PAGE 36 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — OUTPUT TERMINAL P ANEL OVERVIEW

Table of Contents

How to read the output terminal gauges.

The gauges and knobs on the control panel DO NOT effect the generator output in any f ashion. 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 16), 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 19. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

FIGURE 16. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 20. AC Ammeter

(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 17. AC Voltmeter

Change-over switch

(Reading the W-U leg on

the output terminal panel)

FIGURE 18. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 37

DCA-220SSK — OUTPUT TERMINAL PANEL OVER VIEW

Table of Contents

240/120V Hard Wire Hookup

The output terminal panel, when suppling single phase 120 volts, will provide three legs available with 222.2 amps each on three different circuits. (See Figure 23 below .) The voltage selector switch must be set at the single phase 240/120V position.

The output terminal panel, when suppling single phase 240 volts, will provide one leg only with 111.1 amps available. (See Figure 22 below .) The voltage selector s witch must be set at the single phase 240/120V position.

480/240V Hard Wire Hookup

The output terminal panel, when suppling three phase 240 volts, will provide one circuit available at 241 amps with any two wires plus the ground. (See Figure 24 below .) The voltage selector switch must be set at the three phase 480/277V position.

The output terminal panel, when suppling 3 phase 480 volts, will provide one circuit available at 120 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.

FIGURE 21. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 22. Hard Wire Hookup at 240/120V Position

FIGURE 23. Voltage Selector Switch 480/277V Three Phase

Position

FIGURE 24. Hard Wire Hookup at 480/240V Position

PAGE 38 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — OUTPUT TERMINAL PANEL OVERVIEW

Table of Contents

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 25 belo w.)

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 25), can offer SINGLE PHASE power at 480V, 440V, or 416V. After hooking up the hard wires to the lugs as shown in Figure 28 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 26).

FIGURE 26. Voltage

Selector Switch 270/120V

Single Phase Position

FIGURE 25. Voltage Selector Switch 480/277V Single Phase

Position

FIGURE 28. Hard Wire Hookup for Single Phase 480V, 440V,

or 416V

Single Phase: 277V, 254V, or 240V

3 Phase, 480V, 440V, or 416 V olt

The following connection, with the voltage selector switch locked into the 3 phase 480/277V position (See Figure 26), can offer THREE PHASE power at 480V, 440V, or 416V. After hooking up the hard wires to the lugs as shown in figure 28 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 following connection, with the voltage selector switch locked into the 3 phase 480/277V position (See Figure 26), can offer SINGLE PHASE power at 277V, 254V, or 240V. After hooking up the hard wires to the lugs as shown in Figure 29 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 26).

the lowest setting (See Figure 26).

FIGURE 27. Hard Wire Hookup for Three Phase 480V, 440V,

or 416V

FIGURE 29. Hard Wire Hookup for Single Phase 277V, 254V,

or 240V

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 39

DCA-220SSK — OUTPUT TERMINAL PANEL OVERVIEW

Table of Contents

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 30 belo w.)

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 30), can offer SINGLE PHASE power at 240V, 220V, or 208V. After hooking up the hard wires to the lugs as shown in Figure 33 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 31).

FIGURE 31. Voltage

Regulator Knob located

on the control panel

FIGURE 30. Voltage Selector Switch 240/139V Three Phase

Position

FIGURE 33. Hard Wire Hookup for Single Phase 240V, 220V,

or 208V

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 30), can offer THREE PHASE power at 270V, 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 31).

FIGURE 32. Hard Wire Hookup for Three 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 30), can offer SINGLE PHASE power at 139V, 127V, or 120V. After hooking up the hard wires to the lugs as shown in Figure 34 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 31).

FIGURE 34. Hard Wire Hookup for Single Phase 139V, 127V,

or 120V

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DCA-220SSK — OUTPUT TERMINAL PANEL OVERVIEW

Table of Contents

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 35 below)

Single Phase: 120 Volt

The following connection, with the voltage selector switch locked into the single phase 240/120V position (See Figure 35), will offer SINGLE PHASE power at 120V. After hooking up the hard wires to the lugs as shown in Figure 38 below, use the Voltage Regulator Knob to fine tune to 120V. (See Figure 36).

FIGURE 36. Voltage

Regulator Knob

located on the control

panel

FIGURE 35. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 38. Hard Wire Hookup 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 35), will offer SINGLE PHASE power at 240V. After hooking up the hard wires to the lugs as shown in Figure 37 below, use the Voltage Regulator Knob to fine tune to 240V. (See Figure 36)

FIGURE 37. Hard Wire Hookup for Single Phase 240 volt

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 41

DCA-220SSK — INSTALLA TION

Table of Contents

Outdoor Installation

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

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

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

CAUTION :

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

CAUTION

Generator Grounding

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

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

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

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

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

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.

a. Copper - 10 AWG (5.3 mm2) or larger . b . Aluminum - 8 AWG (8.4 mm2) or larger .

2. When grounding the generator (Figure 39) 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 ar ticle 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.

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

NOTE

PAGE 42 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — INSTALLA TION

Table of Contents

Figure 39. Typical Generator Grounding Application

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 43

DCA-220SSK — PRE-SETUP

Table of Contents

General Inspection Prior to Operation

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

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use Cable Selection Guide (Table 10 ) as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 600 amp ,

main

circuit breaker is provided to protect the UVW output

terminals from overload. In addition two single-pole, 20 amp

GFCI

load

circuit breakers

ALL

NOTE

ALWAYS consult with a licensed

electrician for correct extension cord wire size.

circuit

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PAGE 44 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — PRE-SETUP

Table of Contents

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 11 for proper selection of engine oil.

Fuel

Fill the fuel tank with clean and fresh fill the tank beyond capacity.

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

Coolant

diesel fuel.

DO NOT

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.

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator

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.

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

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 45

DCA-220SSK — PRE-SETUP

Table of Contents

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

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Operation in Freezing Weather

When operating in freezing weather, be cer tain the proper

Day-to-day addition of coolant is done from the

amount of antifreeze (Table 13) has been added.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. P eriodically 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. See maintenance section for instruction to cleaning/replacing air cleaner .

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. See maintenance section on replacing belts. To adjust tension:

1. Insert a bar between alternator and the cylinder block to

fix alternator in position. When fixing the alternator in position, insert a wooden block between the bar and alternator to prevent damage to the alternator .

2. Loosen bolts and nuts located on the alternator.

3. Move alternator with the bar so the deflection of the belt

is approx. 8mm.

4. Tighten the bolt and nuts to fix the alternator back to

position.

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NOTE

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

The fan belt tension is proper if the fan belt bends 7 to 10

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mm (Figure 40) when depressed with the thumb as shown below.

Figure 40. Fan Belt Tension

CAUTION

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

PAGE 46 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — PRE-SETUP

Table of Contents

Battery Cable Installation ALWAYS be sure the battery cables (Figure 41) are properly

connected to the battery ter minals as shown below. The

RED

cable is connected to the positive terminal of the battery , and the BLACK cable is connected to the negativ e terminal of the battery.

Figure 41. Battery Connections

CAUTION

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery

terminals when the the manual or auto position (ON). ALWAYS make sure that the Off/Manual/Auto switch is in the OFF position when connecting the battery.

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.

Off/Manual/Auto

switch is in either

CAUTION

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

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

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

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 shor tened, 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 the battery is discharged 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 inhibit corrosion.

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

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 47

DCA-220SSK — LO AD APPLICATION

Table of Contents

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

CAUTION

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 r ated 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.

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

An inadequate size connecting cable which

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 1.0. See Table 14. below when connecting loads.

CAUTION:

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Three Phase Load

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

0.1

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 48 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANU AL)

Table of Contents

WARNING:

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

Before Starting Engine

1. Check the lubricating oil level prior to starting the engine. Make sure the generator is level. The oil level must be maintained between two notches on the dipstick.

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

3. Check the coolant level in the radiator and subtank. Replenish with antifreeze as necessary . Always maintain the coolant lev el between the FULL and LOW markings on the coolant container. Be sure 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

ALWAYS

ventilate the

CAUTION:

Jacket Water Heater and Internal Battery Charger 120 V A C Output Receptacles (OPTIONAL)

This generator is equipped with two 120 V AC , 20 amp output receptacles located on the output terminal panel, page 36, Figure 12.

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

These receptacles will ONLY function when commercial power has been supplied to them (Figure 19). To apply commercial power to these receptacles, a power cord of adequate size will be required.

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jack et water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

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

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

hot

climates there is no reason

cold

climates it is always a good

1. Be sure to disconnect the electrical load and switch the

main, load

the “OFF” position prior to starting the engine.

NEVER start the engine with the

main, GFCI

in the ON position.

and

G.F.C.I.

Figure 42. Main, GFCI and

Load Circuit Breakers

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 49

load

circuit breakers

circuit breakers (Figure 42) to

CAUTION:

ALWAYS have power applied to the generator's internal battery charger

when connecting the generator to a isolation (transfer) switch. Remember before connecting this generator to any buildings electrical system, have a

licensed

installation of the transfer switch.

electrician perform the

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANU AL)

Table of Contents

2. Connect the load to the UVW terminals as shown in

4. Close all engine enclosure doors (Figure 45). Figure 43. These terminals can be found on the output terminal panel, see page 35 Figure 15. To gain access to the output terminals lift the UVW cover . Make sure to tighten terminal nuts securely to prevent load wires from slipping out.

5. Set the battery ON/OFF switch (Figure 46) to the ON position.

Figure 43. UVW Terminal Lugs (Load)

3. Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 44).

Figure 45. Engine Enclosure Doors

NEGATIVE

POSTIVE

BATTERY

Figure 44. Battery Connections

Figure 46. Battery ON/OFF Switch

6. When starting the generator in COLD weather conditions, press and hold the engine preheat button (Figure 47) until the preheat lamp (Figure 48) is lit (ON).

Figure 47. Engine Pre-Heat Button

Figure 48. Engine Pre-Heat Lamp

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DCA-220SSK — GENERATOR START-UP PROCEDURE (MANU AL)

Table of Contents

7. Place the Off/Manual/Auto switch (Figure 49) in the MANUAL position (down). Observe that the engine begins to crank.

11. The generator's voltage meter (Figure 52) displays the

Figure 49. Off/Manual/Auto Switch (Manual)

8. After engine star ts, verify that the "Engine Running" status LED (Figure 50) on the Microprocessor Engine Control Module (MPEC) display is "ON" (lit).

120 VAC in VOL TS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 53) to increase or decrease the desired voltage.

Figure 51. Frequency Meter (Hz)

Figure 50. MPEC Engine Running Status LED

9. If the generator is equipped with a ignition switch, turn the key to “Start” position (Figure 51). Once the engine starts, release the key to the “on” position.

12. The ammeter (Figure 54) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator’s alternator.

Figure 51. Engine Ignition Switch

10. The generator's frequency meter (Figure 52) displays the 60 cycle output frequency in HERTZ.

Figure 52. Voltage Meter (Volts)

Figure 53. Voltage Adjust Control

Knob

Figure 54. Ammeter (No Load)

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 51

DCA-220SSK — GENERATOR START-UP PROCEDURE (MANU AL)

Table of Contents

13. The engine oil pressure gauge (Figure 55) will indicate the oil pressure (kg/ cm

of the engine. Under normal

16. Turn the MAIN, GFCI and LOAD circuit break ers to their "ON" position (Figure 58).

operating conditions the oil pressure should be approximately 25 psi.

Figure 58. Main and GFCI Circuit Breakers

Figure 55. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 56) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees F ahrenheit (Green Zone).

17. Observe the generator's ammeter (Figure 59) 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.

WATER

TEMP

Figure 56. Coolant Temperature Gauge

15. The tachometer (Figure 57) will indicate the speed of the engine when the generator is operating. Under normal

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

operating conditions this speed should be approximately 1800 RPM’s.

Figure 57. Engine Tachometer

Figure 59. Ammeter (Load)

PAGE 52 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAT OR START-UP PROCEDURE (A UT O)

Table of Contents

CAUTION:

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious may result without this transfer switch.

injury

death

CAUTION:

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

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

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

1. Perform steps 1 through 8 (Before Starting, page 43-

45) as outlined in the manual starting procedure.

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

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

4. Place the Off/Manual/Auto switch (Figure 60) in the AUTO position (up).

CAUTION:

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER

attempt to perform any maintenance when the generator is in the auto mode.

5. Continue to follow the steps outline in the man ual start-

Figure 60. Off/Manual Auto Switch

(AUTO)

up procedure (start at step 11, page 46).

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 53

DCA-220SSK — GENERATOR SHUTDO WN PROCEDURE

Table of Contents

Engine Shutdown

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LO AD circuit break ers to the "OFF position".

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

3. Place the Off/Manual/Auto Switch (Figure 61) in the "OFF/

RESET" position.

Figure 61. Off/Manual Auto Switch (OFF)

4. V erify that the "Engine Running" status LED (Figure 62) on the Microprocessor Engine Control Module (MPEC) display is "OFF" (not lit).

Emergency Stop

1. To stop the engine in the event of an emergency, PUSH the emergency stop button ( Figure 63) inward. This button is located on the generator's engine operating panel, see page 32, Figure 11.

CAUTION

Figure 63. Emergency Stop Button

NEVER stop the engine suddenly except

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

Figure 62. MPEC Engine Running

5. Remove the load from the UVW terminal strip (Figure 16).

PAGE 54 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Status LED (OFF)

NO TE P A GE

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 55

DCA-220SSK — MAINTENANCE

Table of Contents

General Inspection

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

Air Cleaner

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

Outer Element:

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

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

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

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

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

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

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

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

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

Inner element (if equipped)

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

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

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

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

5. Install element.

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

Fuel Addition

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

Removing Water from the T ank

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 b y alwa ys k eeping the tank as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system according to the following procedure. To restart after running out of fuel, turn the key switch to the “START” position for 15-30 seconds. Tr y again, if needed. This unit is equipped with an automatic air bleeding system.

Service Daily

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

Cleaning the Fuel Strainer

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

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 14, page 39.

Flushing Out Radiator and Changing Coolant

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

PAGE 56 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

2. Turn water filer cap slowly and remove it.

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

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

DCA-220SSK — MAINTENANCE

Table of Contents

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

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

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

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

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

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

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

Changing Oil

1. Make sure the oil is cool before changing.

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

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

4. Using a filter wrench, turn filter car tridge to the left to remove it. If the filter cartridge is filled with a large amount of oil, wait 10 minutes or so before removing. Make sure there is no old gasket stuck on the filter holder .

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

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

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

Replacing fuel filter

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

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

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

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

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

Check Electric Heater (If equipped)

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

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

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

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

5. After replacing filter cartridge, loosen air b leed plug.

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

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 57

DCA-220SSK — MAINTENANCE

Table of Contents

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

8. Replace Corrosion resistor cartridge (if equipped)

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

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

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

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

13. Open valves.

Cleaning breather element

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

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

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

Greasing

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

Generator Storage

For storage of the generator for over 30 days, the following is required:

Fill the fuel tank completely, lubr icate and change oil.

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

If the ambient temperature is expected to drop below 0oC, add antifreeze to the r adiator.

Removal from long term storage:

Apply oil to the engine valve and rocker arms, and examine the operating condition of the valves.

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

Change the oil in engine oil pan.

Replace all the filters.

Flush the inside of the cooling system.

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

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

PAGE 58 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — MAINTENANCE

Table of Contents

ECNANETNIAM/NOITCEPSNI

srH01

YLIAD

srH052 srH005 srH0001

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

)elbacilppafi(rotarapeSretaWkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

*tnemelErotarapeSretaWecalpeR

)X( X

noitcetorPtnalooCkcehCdnarotaidaRnaelC

leveL

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

smhoM3revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

."retliFrotarapeSretaW"metiehtotrefeR

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 59

DCA-220SSK — GENERAT OR WIRING DIA GRAM

Table of Contents

PAGE 60 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

NOTE PA GE

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 61

DCA-220SSK — ENGINE WIRING DIA GRAM (WITH MPEC)

Table of Contents

PAGE 62 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — ENGINE WIRING DIA GRAM (WITH KEY IGNITION)

Table of Contents

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 63

DCA-220SSK — TROUBLESHOOTING (ENGINE)

Table of Contents

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

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR ?deggolcepipleuF .epipleufnaelC ?deggolcretlifleuF .retlifleufegnahcronaelC

?tungniniaterepip

.tratstonseodenignE

?gnimitnoitcejnitcerrocnI .tsujdA

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

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

GNITOOHSELBUORTENIGNE.51ELBAT

.lioenigneroleufdeificepsehtesU

.tunnethgiT

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?rednilycmorfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

.nurtonseodretratS

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

PAGE 64 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TROUBLESHOOTING (ENGINE)

Table of Contents

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.51ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

.devresbosisag

tsuahxeyargkradrokcalbrehtiE

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

.redlohelzzon

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 65

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-220SSK — TROUBLESHOOTING (GENERATOR/ENGINE)

Table of Contents

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 16) and the MPEC Troubleshooting (Table 17). If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG&ENIGNE.61ELBAT

MOTPMYSMELBORPELBISSOPNOITULOS

?yrettabdaeD.yrettabecalpeR

tonseodretratsdnatratsotsliafenignE

.detator

?hctiwsretratsevitcefeD.hctiwsecalpeR

?tuodenrub5FesuF.esufecalpeR

?tiucrictaeh-erpnekorB.tiucrictaeh-erpkcehC

.setatorretratsdnatratsotsliafenignE

.deepswoltasniamerdnastratsenignE

siegatlovondnasesirdeepsenignE

.ecruosrewopCAnitneserp

rewopCAdnasesirdeepsenignE

.desuebtonnacrowolootsiegatlov

yrettabdnasesirdeepsenignE

.noosootsegrahcsid

?leufoN.leufddA

?gniriwevitcefeD.gniriwkcehC

?reniartsleufdeggolC.ecalperronaelC

?renaelcriadeggolC.ecalperronaelC

?gniriwdetcennocsiD.gniriwriaperdnakcehC

?ecruosrewopCAnitneserpegatlovoN.)1ER(reifitcerecalpeR

?rotorevitcefeD.rotorecalpeR

?retemtlovevitcefeD.retemtlovecalpeR

?gniriwdetcennocsiD.gniriwriaperdnakcehC

?gnidniwerutamranitiucric-trohsreyaL.erutamraecalpeR

?)rotcetorp(rekaerbtiucricevitcefeD .)rotcetorp(rekaerbtiucricecalpeR

erutamraniseriwnekorb,tiucric-trohsreyaL

?gnidniw

?rotalugerenigneevitcefeD.rotalugerecalpeR

?gniriwevitcefeD.gniriwecalperroriapeR

.erutamraecalperroriapeR

.dedaolrevo

PAGE 66 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

smeesenignednasesirdeepsenignE

?rotanretlaevitcefeD .rotanretlaecalperroriapeR

?gniraebrotanretladegamaD .sgniraebrotanretlaecalpeR

DCA-220SSK — TROUBLESHOOTING (MPEC)

Table of Contents

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

GNITOOHSELBUORTCEPM.71ELBAT

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

thgilleveltnaloocwoL

.nosi

erutrepmettnaloochgiH

.nosithgil

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR ?CEPMninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenCEPM.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

.nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenCEPM.relaedotrefeR

ro)s(thgilUPMfossoL

.no

?ytridpukcipcitengaM .pukcipcitengamnaelC

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 67

EXPLANA TION OF CODE IN REMARKS COLUMN

Table of Contents

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

Serial Numbers Pertaining to Unit DCA-220SSK Standard:

Up to S/N3696500 S/N3699150 to S/N3699619 S/N3699637 to S/N3703349 S/N3703364 to S/N3703853 S/N3703869~

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,

■

, 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.

, #, +, %, or

PAGE 68 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — SUGGESTED SPARE PARTS

Table of Contents

DCA-220SSK W/KOMATSU S6D125E-2 DIESEL ENGINE

1 to 5 Units

Qty. P/N Description

10 .......6125817032 ............. AIR FILTER

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

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

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

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

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

2 .........0601810204 ............. BULB, ENGINE TROUBLE

2 .........0412122265 ............. ENGINE FAN BELT

1 .........6008155390 ............. SWITCH, STARTER

5 .........615........................... KEY SET, STARTER SWITCH (2)

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

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

1 .........6151619330 ............. RADIATOR HOSE (LO WER)

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

1 .........0601820625 ............. AUT OMATIC VOLT A GE REGULA T OR

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

1 .........0601840121 ............. KNOB, VOL T A GE REGULA T OR

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

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

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

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

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

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

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 69

GENERATOR ASSY. UP TO S/N1337562

Generator S/N1337562~

Table of Contents

DCA-220SSK — GENERAT OR ASSY.

PAGE 70 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAT OR ASSY.

Generator up to S/N1337562

Generator S/N1337562~

Table of Contents

GENERATOR ASSY. UP T O S/N1337562

NO PART NO PART NAME QTY. REMARKS

1 8181000002 ROT OR ASSY. 1 1-1 FIELD ASSY. 1 1-2 8171070002 F AN 1 1-3 0012112040 HEX. HEAD BOLT 8 1-4 0042512000 LOCK WASHER 8 1-5 8171611003 COUPLING DISK 9 1-6 8171015003 BALANCING PLATE 1 1-7 0012116040 HEX. HEAD BOLT 8 1-8 0042616000 LOCK WASHER 8 1-9 8171026003 SET PLATE, RECTIFIER 1

1-10 0601821349 RECTIFIER................................................3........ PT 3610

1-11 0601822615 SURGE ABSORBER .................................1........ ERZ-M20JK621B

1-12 8171020004 INSULA T OR WASHER 1 1-13 8171020504 INSULA T OR WASHER 1 1-14 0010110020 HEX. HEAD BOLT 6 1-15 0040010000 LOCK W ASHER 6 1-16 0601000209 BALANCING WEIGHT KIT 1

1-17 0070806312 BEARING...................................................1 ........ 6312 DU

1-18 0080000060 SNAP RING 1 2 8171614003 COUPLING RING 1 3 0012112035 HEX. HEAD BOLT 8 4 0042512000 LOCK W ASHER 8 5 8181340303 STA T OR ASSY. 1 5-1 0226100430 RUBBER SEAL 1 6 8171323004 CLAMPER 1 6-1 0223300120 RUBBER SEAL 1 7 8171323103 CLAMPER 1 7-1 0221200300 RUBBER SEAL 1 8 0010110035 HEX. HEAD BOLT 2

9 031110160 PLAIN WASHER ........................................2........ REPLACES 0041610000

10 8171324003 CO VER 1 10-1 0226000270 R UBBER SEAL 2 10-2 0225000480 R UBBER SEAL 1 11 0010106016 HEX. HEAD BOLT 6 12 0040006000 LOCK W ASHER 6

13 031110160 PLAIN WASHER ........................................6........ REPLACES 0041606000

14 8171315002 END BRACKET 1 15 8171350003 FIELD ASSY., EXCITER 1 16 0012110060 HEX. HEAD BOLT 6 17 0042610000 LOCK W ASHER 6

18 031110160 PLAIN WASHER ........................................6........ REPLACES 0041610000

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 71

GENERATOR ASSY. UP TO S/N1337562

Generator S/N1337562~

Table of Contents

DCA-220SSK — GENERAT OR ASSY.

PAGE 72 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAT OR ASSY.

Generator up to S/N1337562

Generator S/N1337562~

Table of Contents

GENERATOR ASSY. UP T O S/N1337562

NO PART NO PART NAME QTY. REMARKS

19 0845044904 GROMMET 1

20 012212045 HEX. HEAD BOLT...................... 8 ......... REPLACES 0010112045

21 0040012000 LOCK W ASHER 8

22 031112230 PLAIN WASHER ........................8 .........REPLACES 0041612000

23 8171310004 COVER, BEARING 1 24 8171312004 GASKET, BEARING 1 25 8171331003 COVER, END BRACKET 1 26 0010106016 HEX. HEAD BOLT 12 27 0040006000 LOCK W ASHER 12

28 952404470 PLAIN WASHER ........................1 2........ REPLACES 0041606000

29 8171333003 COVER, END BRACKET 1 30 0010106030 HEX. HEAD BOLT 2 31 0040006000 LOCK W ASHER 2

32 952404470 PLAIN WASHER ........................2 .........REPLACES 0041606000

33 0012112035 HEX. HEAD BOLT 12 34 0042512000 LOCK W ASHER 12 35 8171332003 COVER, FAN 1 36 0605000012 RUBBER SUSPENSION 2 37 0030020000 HEX. NUT 4

38 030220510 LOCK WASHER ......................... 4 ......... REPLACES 0040020000

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 73

GENERATOR ASSY. S/N1337563~

Generator up to S/N1337562

Table of Contents

DCA-220SSK — GENERAT OR ASSY.

PAGE 74 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAT OR ASSY.

Generator up to S/N1337562

Generator S/N1337562~

Table of Contents

GENERATOR ASSY. S/N1337563~

NO PART NO PART NAME QTY. REMARKS

1 C1110100202 ROTOR ASSY. 1 1-1 FIELD ASSY. 1

1-2 0601842334 RESISTOR............................................ 1 ..........SMRK 80W 100KOHM

1-3 0601823282 RECTIFIER ........................................... 1 ..........RM50TC24

1-7 0018205020 HEX. SOCKET HEAD CAP SCREW 2

0040005000 LOCK W ASHER 2

0041205000 PLAIN W ASHER 2 1-8 8171070002 FAN 1 1-9 8171611003 COUPLING DISK 9 1-10 C1164200004 WASHER, COUPLING HUB 1 1-11 8171015003 BALANCING PLATE 1 1-12 0012116045 HEX. HEAD BOLT 8 1-13 0042616000 LOCK W ASHER 8 1-14 0601000209 BALANCING WEIGHT KIT 1 1-15 C1112500004 BEARING FLANGE 1

1-16 0071906314 BEARING.............................................. 1 ..........6314DDUC3

2 8171614003 COUPLING RING 1 3 0012112035 HEX. HEAD BOLT 8 4 0042512000 LOCK W ASHER 8 5 0012112040 HEX. HEAD BOLT 8 6 0042512000 LOCK W ASHER 8 7 C1130100103 STATOR ASSY. 1 7-1 0226100420 RUBBER SEAL 1 7-2 8171323004 CLAMPER 1 7-3 0223300120 RUBBER SEAL 1 7-4 8171323103 CLAMPER 1 7-5 0221200300 RUBBER SEAL 1 7-9 0010110035 HEX. HEAD BOLT 2 7-7 0041210000 PLAIN WASHER 2 7-8 C1132200003 COVER 1 7-9 0226000510 RUBBER SEAL 2 7-10 0225000470 R UBBER SEAL 1 7-11 0017106016 HEX. HEAD BOLT 6 7-12 0601850144 GROMMET 1 8 C1154000002 END BRACKET 1 9 C1138000003 FIELD ASSY. EXCITER 1

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 75

GENERATOR ASSY. S/N1337563~

Generator up to S/N1337562

Table of Contents

DCA-220SSK — GENERAT OR ASSY.

PAGE 76 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAT OR ASSY.

Generator up to S/N1337562

Generator S/N1337562~

Table of Contents

GENERATOR ASSY. S/N1337563~

NO PART NO PART NAME QTY. REMARKS

10 0012110065 HEX. HEAD BOLT 4

0042610000 LOCK W ASHER 4

0041210000 PLAIN W ASHER 4 11 0017112045 HEX. HEAD BOLT 6 12 C1154400004 COVER, BEARING 1 13 C1154300004 GASKET, BEARING 1 14 0010106065 HEX. HEAD BOLT 4

0040006000 LOCK W ASHER 4

0041206000 PLAIN W ASHER 4 15 C1154400103 SUCTION CO VER 1 16 0017106016 HEX. HEAD BOLT 8 17 0012112035 HEX. HEAD BOLT 12 18 0042512000 LOCK W ASHER 12

19 C1132300103 COVER, FAN ........................................ 1 ..........S/N3690735 TO 3692206

19 C1132300114 COVER, FAN ........................................ 1 ..........S/N3692207~

20 0010106030 HEX. HEAD BOLT 1

0041206000 PLAIN W ASHER 1

0600815000 NU T....................................................... 1 ..........S/N3692207~

21 0605000012 RUBBER SUSPENSION 2 22 0030020000 HEX. NUT 4

0040020000 LOCK W ASHER 4

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 77

DCA-220SSK — CONTROL BO X AND PANEL ASSY.

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL PANEL ASSY. UP TO S/N1337562

PAGE 78 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BO X AND PANEL ASSY.

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL PANEL ASSY. UP TO S/N1337562

NO. PART NO. PART NAME QTY. REMARKS

1 8181812502 CONTROL BO X 1

2 0601801167 TRANSFORMER, AMMETER ............................ 2 ...... CT5MR 400/5A

3 0027106010 MACHINE SCREW 4

4 0601805950 CIRCUIT BREAKER ........................................... 1 ...... TO-600CA 600A

5 0601820625 AUTOMATIC VOLT AGE REGULA TOR 1 6 0027105012 MACHINE SCREW 4

7 0601820193 CONDESER ........................................................ 1 ...... 40FAL 155U#L2

8 0027103010 MACHINE SCREW 2

9 0601820851 OVER CURRENT RELAY.................................... 1 ...... THK20

10 0027104016 MACHINE SCREW 2

11 0601823757 RELAY ................................................................ 2 ...... MY2 DC24V

12 0601823143 SOCKET, RELAY ................................................ 2 ...... PYF 08A

PYCA1 HOLDER ............................................................. 2 ...... REPLACES 0601824400

13 0027104016 MACHINE SCREW 4

14 0601823240 RECTIFIER ......................................................... 1 ...... DE4503

15 0027105016 MACHINE SCREW 1 16 0801850004 RESISTOR UNIT 1 17 0021005020 MACHINE SCREW 1

0040050000 LOCK WASHER 1

0041205000 PLAIN WASHER 1

0030006000 HEX. NUT 1

18 0601830715 SELECT OR SWITCH, VOLTA GE ........................ 1 ...... S332T

19 8181861103 SET BOARD, CHANGE TERMINAL 1 20 8181852104 CHANGE TERMINAL 10 21 0017106025 HEX. HEAD BOLT 20 22 8181853104 CHANGE PLATE 6 23 8131852504 HEX. HEAD BOLT 10 24 0801831804 HEX. HEAD BOLT 16 25 0040010000 LOCK W ASHER 2 6 26 0041410000 PLAIN W ASHER 26 27 0017108030 HEX. HEAD BOLT 4 28 8181822603 CONTROL PANEL 1 29 8181822503 CONTROL PANEL 1 29-1 0225100095 RUBBER SEAL 4 30 0605011211 PIN 4

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 79

DCA-220SSK — CONTROL BO X AND PANEL ASSY.

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL PANEL ASSY. UP TO S/N1337562

PAGE 80 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BO X AND PANEL ASSY.

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL PANEL ASSY. UP TO S/N1337562

NO. PART NO. PART NAME QTY. REMARKS

31 0601800470 FREQ. METER.................................................... 1 ...... PAK80 220V 45~65Hz

32 0601805726 AC AMMETER .................................................... 1 ...... PSK80 0~400A

33 0601801040 CHG.-OVR. SW, AMMETER ............................... 1 ...... SL2VS

34 0601800239 AC VOLTMETER ................................................. 1 ...... PCK80 0~600V

35 0601801041 CHG.-O VR.SW, V OL TMETER ............................. 1 ...... SL2AS

36 0601810072 PILOT LAMP ....................................................... 1 ...... LP132DC 220V

0601810261 BULB 1

37 0601840073 RHEOSTA T (V OL TAGE REGULATOR) ................ 1 ...... RA20A2SE102BJ

38 0601840121 KNOB 1

39 0601822408 EARTH LEAKAGE RELAY ................................. 1 ...... TZS15HCD 30mA

39-1 0601802810 0-PHASE SEQ. TRANSFORMER ....................... 1 ...... TZS15

40 0840303303 BRACKET, EARTH LEAKAGE RELAY 1 41 0021004020 MACHINE SCREW 2

0040004000 LOCK WASHER 2

0041204000 PLAIN WASHER 2 42 0027104010 MACHINE SCREW 2 43 0027104010 MACHINE SCREW 4

44 0601810072 SYNCHRONIZING LAMP.................................... 2 ...... LD132DC 220V

0601810261 BULB 2

45 0601830682 SELECTOR SW. SINGLE/PAR............................ 1 ...... AH30P2B31

46 0601810161 PANEL LIGHT ..................................................... 1 ...... V325070

0601810214 BULB 1 47 0207004000 HEX. NUT 2

48 0601830710 SWITCH, PANEL LIGHT ..................................... 1 ...... S301T

49 7431822104 CO VER 1 50 0027103016 MACHINE SCREW 4

0030003000 HEX. NUT 4 51 0805001304 SET SCREW 4 52 0041608000 PLAIN W ASHER 4 53 0605010710 SNAP RING 4 54 3871824004 STOPPER, CONTROL PANEL 2 55 0041606000 PLAIN W ASHER 2 56 0605010502 SNAP PIN 2 57 8181814504 COVER, CONTR OL 1 58 0017106016 HEX. HEAD BOLT 13 59 8181826504 SIDE PANEL, CONTROL BOX 2 60 0017106016 HEX. HEAD BOLT 16 61 8181827503 PANEL, CONTROL BOX 1 62 0017106016 HEX. HEAD BOLT 12 63 0010010025 HEX. HEAD BOLT 4

0030010000 HEX. NUT 4

0040010000 LOCK WASHER 4

0041610000 PLAIN WASHER 8

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 81

DCA-220SSK — CONTROL BO X ASSY. (OPTIONAL PARTS)

Table of Contents

CONTROL BOX ASSY. (OPTIONAL PARTS) UP T O S/N1337562

PAGE 82 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)

Control Box (Options) up to S/N1337562

Table of Contents

CONTROL BOX ASSY. (OPTIONAL PARTS) UP T O S/N1337562

NO PART NO PART NAME QTY. REMARKS

1 8181812502 CONTROL BO X 1

2 0601801167 CURRENT TRANSFORMER, AMMETER ... 2 ........ CT5MR 440/5A

3 0027106010 MACHINE SCREW 4

4 0601805950 CIRCUIT BREAKER.................................... 1........ TO600CA 600A

5 0601820625 AUTOMATIC VOL T AGE REGULA TOR ......... 1 ........ NT A-5A-27

6 0027105012 MACHINE SCREW 4

7 0601820193 CONDENSER.............................................. 1 ........ 40FAL155U #L2

8 0027103010 MACHINE SCREW 2

9 0601820851 OVER CURRENT RELAY............................ 1 ......THK20

10 0027104016 MACHINE SCREW 2

11 0601823757 RELAY......................................................... 2 ........ MY2DC24V

12 0601823143 SOCKET , RELAY ........................................ 2 ........ PYF08A

PYCA1 HOLDER...................................................... 2 ........ REPLACES 0601824400

13 0027104016 MACHINE SCREW 4

14 0601821370 RECTIFIER ................................................. 1 ........ DE4503 REPLACES 0601823240

15 0027105016 MACHINE SCREW 1 16 0801850004 RESISTOR UNIT 1 17 0021005020 MACHINE SCREW 1

0032005000 LOCK WASHER .......................................... 1 ........ REPLACES 0040005000

0401450050 PLAIN WASHER.......................................... 1........ REPLACES 0041205000

020106050 HEX. NUT.................................................... 1 ........ REPLACES 0030006000

18 0601830715 SELECTOR SWITCH, V O LTAGE................. 1 ........ S332T

19 8181861103 SET BOARD, CHANGE TERMINAL 1 20 8181852104 CHANGE TERMINAL 10

21 011606025 HEX. HEAD BOLT ....................................... 20 ...... REPLACES 0017106025

22 8181853104 CHANGE PLATE 6 23 8131852504 HEX. HEAD BOLT 10

24 012210020 HEX. HEAD BOLT ....................................... 16 ...... REPLACES 0801831804

25 0040010000 LOCK WASHER 26 26 0041410000 PLAIN WASHER 2 6

27 011208030 HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0017108030

28 8181833003 SET PANEL, ELECTRIC PARTS 1

29 011008020 HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0017108020

30 0601823704 REVERSE POWER RELAY 1 31 0027104010 MACHINE SCREW 4 32 8181822603 CONTROL PANEL 1 33 8181822503 CONTROL PANEL 1 33-1 0225100095 RUBBER SEAL 4

34 0605011211 PIN .............................................................. 4 ........ B-99-2

35 0601800470 FREQUENCY METER ................................ 1 ........ PAK80 220V 45~65HZ

36 0601800790 AC AMMETER ............................................ 1 ........ PSK80 0~400A 0~800A

REPLACES 0601805726

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 83

DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)

Table of Contents

CONTROL BOX ASSY. (OPTIONAL PARTS)UP TO S/N1337562

PAGE 84 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)

Control Box (Options) up to S/N1337562

Table of Contents

CONTROL BOX ASSY. (OPTIONAL PARTS)UP TO S/N1337562

NO PART NO PART NAME QTY. REMARKS

37 0601801040 CHANGE-OVER SWITCH, AMMETER....... 1 ........ SL2AS

38 0601800239 AC VOLTMETER ......................................... 1 ........ PCK80 0~600V

39 0601801041 CHANGE-OVER SWITCH, AMMETER....... 1 ........ SL2 VS

40 0601800570 AC WATTMETER......................................... 1........ PWTK8020~0~200kW

INCLUDE ITEM W/#

40-1# 0601804021 TRANSDUCER, W A TTMETER .................... 1 ........ WT64M

41 0027104010 MACHINE SCREW 4

42 0601810072 PILOT LAMP ............................................... 1 ........ LP132DC 220V

0601810261 BULB, 13W 1

43 0601840073 RHEOSTA T (V OLT A GE REGULATOR)......... 1 ........ RA20A2SE102BJ

44 0601840121 KNOB 1

45 0601822408 EARTH LEAKAGE RELAY .......................... 1........ TZS15HC-D 30mA

INCLUDE ITEM W/+

45-1+ 0601802810 ZERO-PHASE-SEQUENCE

CURRENT TRANSFORMER ....................... 1 ........ TZS-15

46 0840303303 BRACKET, EARTH LEAKAGE RELAY 1 47 021004020 MACHINE SCREW 2

040004000 LOCK WASHER 2

031104080 PLAIN WASHER.......................................... 2 ........ REPLACES 0041204000

48 0027104010 MACHINE SCREW 2 49 0027104010 MACHINE SCREW 4

50 0601810072 SYNCHRONIZING LAMP............................ 2 ........ LD132DC 220V

0601810261 BULB, 13W 2

51 0601830682 SELECTOR SWITCH, SINGLE/PAR. .......... 1........ AH30P2B31

52 0601910161 PANEL LIGHT ............................................. 1 ........ V 325070

0601810214 BULB 1

53 0030004000 HEX. NUT.................................................... 2 ........ REPLACES 0207004000

54 0601830710 SWITCH, PANEL LIGHT 1 55 0805001304 SET SCREW 4

56 031108160 PLAIN WASHER.......................................... 4 ........ REPLACES 0041608000

57 0605010710 SNAP RING 4 58 3871824004 STOPPER, CONTROL PANEL 2

59 952404470 PLAIN WASHER.......................................... 2 ........ REPLACES 0041606000

60 505015300 SNAP RING ................................................ 2........ REPLACES 0605010502

61 8181814504 COVER, CONTROL BOX 1 62 0017106016 HEX. HEAD BOLT 13 63 8181826504 SIDE PANEL , CONTROL BOX 2 64 0017106016 HEX. HEAD BOLT 16 65 8181827503 PANEL, CONTROL BOX 1 66 0017106016 HEX. HEAD BOLT 12

67 0105091025 HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0010010025

020310080 HEX. NUT.................................................... 4 ........ REPLACES 0030010000

0040010000 LOCK WASHER 4

031110160 PLAIN WASHER.......................................... 8 ........ REPLACES 0041610000

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 85

CONTROL PANEL ASSY. S/N1337563~

Control Box and Panel up to S/N1337562

Cont. Box S/N1337563~

Table of Contents

DCA-220SSK — CONTROL PANEL ASSY.

PAGE 86 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL PANEL ASSY.

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL PANEL ASSY. S/N1337563~

NO. PART NO. PART NAME QTY. REMARKS

1 C1224000503 CONTROL P ANEL 1 2 C1224000603 CONTROL P ANEL 1 3 0605011211 PIN 2

4 0601807622 FREQ. METER ............................................. 1 ............ RSC80F 45~65Hz 200V

5 0601806980 AC AMMETER.............................................. 1............ RSS80 0~400A

6 0601801040 CHG.OVR. SW.-AMMETER .......................... 1............ SL2AS

7 0601806887 AC VOLTMETER........................................... 1 ............ RSR80 0~600V

8 0601801041 CHG.OVR.SW -VOLTMETER......................... 1 ............ SL2VS

9 0601810072 PILOT LAMP................................................. 1............ KO132DC 220V

0601810261 BULB 1

10 0601840073 RHEOST AT (VOLT A GE REGULATOR) .......... 1............ RA20A2SE102BJ

11 060184012 KNOB 1 12 0601810161 PANEL LIGHT 1

0601810214 BULB 1 13 0207004000 HEX. NUT 2 14 0601830710 SWITCH, PANEL LIGHT 1 15 C9221100004 HEX. HEAD BOLT 2

0040008000 LOCK WASHER 2

0041208000 PLAIN WASHER 2

0080200007 SNAP RING 2 16 0017108040 HEX. HEAD BOLT 4

17 ECU9988N* ENGINE CONTROLLER ............................... 1 ............ REPLACES 0602202545

18 0601831340 SWITCH,82608DPDT.................................... 1 ............ S/N3696501 TO3698120

18 0601830765 SWITCH,S3037;............................................ 1............ S/N3698121~

19 DYNT11100 SPEED SENSOR ......................................... 1............ S/N3696501~;

REPLACES 0602120497

*NOTE:

WHEN ORDERING PART NUMBER 17,

PLEASE INDICATE SERIAL NUMBER.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 87

CONTROL BOX ASSY. S/N1337563~

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Table of Contents

DCA-220SSK — CONTROL BO X ASSY.

PAGE 88 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BO X ASSY.

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL BOX ASSY. S/N1337563~

NO. PART NO . PART NAME QTY. REMARKS

1 C1214000412 CONTROL BO X..................................... 1 ..........S/N 1337563 T O3690734

1 C1214000422 CONTROL BO X..................................... 1 ..........S/N3690735~

2 0601806133 TRANSFORMER, AMMETER ..............3 ..........CT5MRN

3 0027106016 MACHINE SCREW 6

4 0601807364 CIRCUIT BREAKER .............................1 ..........XE600NS 600A

4-1 0601802525 HANDLE, CIRCUIT BREAKER 1

5 0601820625 AUTOMATIC VOL T AGE REGULA TOR ... 1 ..........NT A5A2T

6 0027105016 MACHINE SCREW 4

7 0601820892 OVER CURRENT RELAY......................1 ..........THN20HZKP3.6A

8 0027104016 MACHINE SCREW 2 9 0601824542 RELAY 2 10 0027103010 MACHINE SCREW 4 11 C1274000103 SET BOARD CHANGE TERMINAL 1 12 8181852104 CHANGE TERMINAL 10 13 0017106025 HEX. HEAD BOLT 20 14 8181853104 CHANGE PLATE 6 15 8131852504 HEX. HEAD BOLT 13 16 C0277200004 TERMINAL PLATE 3 17 0801831804 HEX. HEAD BOLT 13 18 0040010000 LOCK WASHER 26 19 0041410000 PLAIN WASHER 26 20 0017108030 HEX. HEAD BOLT 4

21 C1261500114 SET PANEL, ELECTRIC PARTS ..........1 ..........S/N1337563 TO 3696500

21 C1261501304 SET PANEL, ELECTRIC PARTS ..........4 ..........S/N3696501~

22 0017108020 HEX. HEAD BOLT 4

23 6008151252 EMERGENCY RELAY .......................... 1 ..........S/N3690735 TO 3701661

REPLACES0602200446

24 0017106016 HE.X HEAD BOLT ................................ 4 ..........S/N3690735 TO 3701661

25 0602201911 UNIT, BATTERY SENSOR .................... 1 ..........C7038A0000

26 0027106016 MACHINE SCREW 1 27 3871824004 STOPPER, CONTROL PANEL 1 28 0041206000 PLAIN WASHER 1 29 0605010502 SNAP PIN 1 30 C1214500004 COVER, CONTROL BO X 1 31 0017108020 HEX. HEAD BOLT 8 32 C1214300004 SIDE PANEL, CONTROL BOX 1 33 0017108020 HEX. HEAD BOLT 4 34 C1214400004 PANEL, CONTROL BOX 1 35 0017108020 HEX. HEAD BOLT 8 36 0017110025 HEX. HEAD BOLT 4

37 0601823861 STOP UNITMSA9014............................ 1 ..........S/N3696501 TO 3701661

38 0027104010 MACHINE SCREW ...............................2 ..........S/N3696501 TO 3701661

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 89

CONTROL BOX ASSY. S/N1337563~

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Table of Contents

DCA-220SSK — CONTROL BO X ASSY.

PAGE 90 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — CONTROL BO X ASSY.

Control Box and Panel up to S/N1337562

Cont. Panel S/N1337563~

Cont. Box S/N1337563~

Table of Contents

CONTROL BOX ASSY. S/N1337563~

NO. PART NO . PART NAME QTY. REMARKS

39 0601823240 RECTIFIER;DE4503 .............................4 ..........S/N3696501 TO 3701661

40 0027104030 MACHINE SCREW ...............................2 ..........S/N3696501 TO 3701661

41 0601802149 FUSE;10A 1

0601806671 FUSE;15A ............................................. 1 ..........S/N3701662~

0601802218 HOLDER, FUSE.................................... 1 ..........S/N3696501~

42 0027103020 MACHINE SCREW ...............................1 ..........

43 0601823732 RELAY;LY2DC24V................................. 1 ..........S/N6396501 TO3699126

0601827655 RELAY;LY2DDC24V ..............................1 ..........S/N369501~

0601823109 SOCKET;PTF08A ................................. 1 ..........S/N369501~

PYCA1 HOLDER ...............................................1 ..........S/N3696501~;REPLACES 0601824400

44 0027104020 MACHINE SCREW ...............................2 ..........S/N3696501~

45 0601823706 RELA Y ;HE1ADC24V ............................. 1 .......... S/N3696501~

46 0027104010 MACHINE SCREW ...............................2 ..........S/N3696501~

47 0601815402 TERMINAL BOARD .............................. 1 ..........S/N3696501~

48 0027104020 MACHINE SCREW ...............................2 ..........S/N3696501~

49 DYN110654000024 CONTROLLER ...................................... 1 ..........S/N3701662~;REPLACES 0602202598

50 DYNT11200 SPEED SENSOR.................................. 1 ..........S/N3701662~;REPLACES 0602120498

51 0027104020 MACHINE SCREW ...............................4 ..........S/N3701662~

52 0601840009 RHEOSTAT;RA20A2SE502BJ .............. 1 ..........S/N3701662~

53 C3262600004 BRACKET ............................................. 1 ..........S/N3701662~

54 0017106015 HEX. HEAD BOLT.................................1 ..........S/N3701662~

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 91

DCA-220SSK — ENGINE & RADIATO R ASSY.

S/N1337563 to 3690734

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. UP TO S/N1337562

PAGE 92 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N1337563 to 3690734

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. UP TO S/N1337562

NO PART NO PART NAME QTY. REMARKS

1 0602000123 ENGINE ................................................... 1 .........S6D125-1

2 615619350 RADIATOR................................................ 1 .........REPLACES 0602011866

3 615619340 RUBBER SHEET...................................... 2 .........REPLACES 0605000073

4 0010012045 HEX. HEAD BOLT 4 5 0030012000 HEX. NUT 4 6 0040012000 LOCK WASHER 4 7 0041612000 PLAIN WASHER 4 8 8185123004 BRACKET, RADIATOR 2 9 0017110025 HEX. HEAD BOLT 6

10 6151619320 RADIATOR HOSE .................................... 1 .........REPLACES 0602013976

11 6151619330 RADIATOR HOSE .................................... 1 .........REPLACES 0602014469

12 0726020980 RADIATOR HOSE .................................... 1 .........REPLACES 0602013977

13 0728100909 HOSE BAND ............................................ 2 .........REPLACES 0602014056

14 0728100809 HOSE BAND ............................................ 2 .........REPLACES 0602014067

15 0728101029 HOSE BAND ............................................ 1 .........REPLACES 0602014350

16 0728100197 HOSE BAND ............................................ 2 .........REPLACES 0602014058

17 0728001920 AIR CLEANER ......................................... 1 .........REPLACES 0602040057

6125817032 ELEMENT, AIR CLEANER ....................... 1 .........REPLACES 0602040156

18 6001811510 CAP, AIR CLEANER ................................ 1 .........REPLACES 0602040751

19 6203306104 SOCKET 1 20 0603301000 ELBOW UNION 1 21 0603302000 SLEEVE 1 22 0603303000 NUT 1

23 6002111231 CARTRIDGE, OIL FILTER ....................... 1 .........REPLACES 0602041146

24 6003118293 CARTRIDGE, FUEL FILTER .................... 2 .........REPLACES 0602042146

25 6004111151 CARTRIDGE, CORROSION RESISTOR 1 REPLACES 0602045147 &

6004111020 26 8185112004 ENGINE FOOT 1 27 0010018060 HE.X HEAD BOLT 2 28 0030018000 HEX. NUT 2 29 0040018000 LOCK WASHER 2 30 0041618000 PLAIN WSAHER 4 31 060500011 RUBBER SUSPENSION 2 32 0030016000 HEX. NUT 4 33 0040016000 LOCK WASHER 4 34 7492025104 DRAIN JOINT 1 35 0017108025 HEX. HEAD BOLT 2 36 0131904000 CAP 1 37 7492026104 DRAIN HOSE 1 38 0605515091 HOSE BAND 2 39 0802081003 RESERVE TANK 1

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 93

DCA-220SSK — ENGINE & RADIATO R ASSY.

S/N1337563 to 3690734

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. UP TO S/N1337562

PAGE 94 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N1337563 to 3690734

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. UP TO S/N1337562

NO PART NO PART NAME QTY. REMARKS

40 0602010900 CAP, RESERVE TANK 1 41 8182082103 BRACKET, RESERVE TANK 1 42 0225000600 RUBBER CUSHION 1 43 0017106025 HEX. HEAD BOLT 1 44 0017108020 HEX. HEAD BOLT 2 45 0199601100 HOSE 1 46 0193601400 HOSE 1 47 0193600500 HOSE 1 48 0605515024 HOSE BAND 4 49 0194800750 HOSE 1 50 0605515000 HOSE BAND 1 51 8185199004 PANEL 1 52 0010016020 HEX. HEAD BOLT 2 53 0040016000 LOCK WASHER 2 54 0041616000 PLAIN WASHER 2 55 8182256304 SUPPORT ROD 1 56 0017110020 HEX. HEAD BOLT 2 57 8182256104 SUPPORT ROD 1 58 0017108016 HEX. HEAD BOLT 2

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 95

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734

PAGE 96 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N1337563 to 3690734

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. S/N1337563 T O3690734

NO PART NO PART NAME QTY. REMARKS

1 C1924200024 ENGINE ......................................................1............ K OMA TSU S6D125E-2

1-1 6125817032 ELEMENT, AIR CLEANER .......................... 1............REPLACES 0602040156

1-2 6002111231 CARTRIDGE, OIL FILTER ..........................1............ REPLACES 0602041146

1-3 6003118293 CARTRIDGE, FUEL FILTER .......................1............REPLACES 0602042146

1-4 6004111151 CARTRIDGE, CORROSION RESIST OR.....1............REPLACES 0602045143

1-5 0602040678 DUST SENSOR; .........................................1............REX018126

2 8185112004 ENGINE FOOT 1 3 0010118060 HEX. HEAD BOLT 2 4 0030018000 HEX. NUT 2 5 0040018000 LOCK WASHER 2 6 0041218000 PLAIN WASHER 4 7 0605000011 RUBBER SUSPENSION 2 8 0030016000 HEX. NUT 4 9 0040016000 LOCK WASHER 4

10 6252619720 RADIATOR................................................... 1............REPLACES 0602011946

11 6152619170 RUBBER SHEET.........................................2............REPLACES 0605000490

12 0010112050 HEX. HEAD BOLT 4 13 0030012000 HEX. NUT 4 14 0040012000 LOCK WASHER 4 15 0041212000 PLAIN WASHER 8 16 8195123104 BRACKET, RADIATOR 2 17 0017112025 HEX. HEAD BOLT 2 18 0017110025 HEX. HEAD BOLT 2

19 6152621520 RADIATOR HOSE .......................................1............REPLACES 0602014513

20 6152611531 RADIATOR HOSE .......................................1............REPLACES 0602014641

21 0726120911 RADIATOR HOSE .......................................1............REPLACES 0602014541

22 0728100809 HOSE BAND ...............................................6............ REPLACES 0602014067

23 0728100909 HOSE BAND ...............................................2............ REPLACES 0602014056

24 0728100197 HOSE BAND ...............................................2............ REPLACES 0602014058

25 3972054104 DRAIN JOINT 1 26 3972054304 PACKING 1 27 C9601000104 DRAIN JOINT 1 28 0017108025 HEX. HEAD BOLT 2 29 0131508000 NIPPLE 1 30 0603325017 VAL VE 1

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 97

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N3690735~

Table of Contents

ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734

PAGE 98 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — ENGINE & RADIATOR ASSY.

Engine up to S/N1337562

S/N3690735~

S/N1337563 to 3690734

Table of Contents

ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734

NO PART NO PART NAME QTY. REMARKS

31 0602022294 HOSE JOINT 1 32 0265800260 DRAIN HOSE 1 33 0605515074 HOSE BAND 2 34 0132008000 PLUG 1 35 0802081003 RESERVE TANK 1 36 0602010900 CAP, RESERVE TANK 1 37 C1317100103 BRACKET, RESERVE TANK 1 38 0193601300 HOSE 1 39 0199601300 HOSE 1 40 0193600550 HOSE 1 41 0605515013 HOSE BAND 4 42 0194800750 HOSE 1 43 C1327100103 BREATHER PIPE 1 44 0017108020 HEX. HEAD BOLT 2 45 0603320111 U BO LT 1 46 0207008000 HEX. NUT 2 47 0268500650 HOSE 1 48 0605515073 HOSE BAND 2 49 C1358300804 CLAMPER ROD 1 50 0017110020 HEX. HEAD BOLT 4 51 C1358300104 CLAMPER ROD 1 52 0017110020 HEX. HEAD BOLT 1 53 0010016030 HEX. HEAD BOLT 1 54 0040016000 LOCK WASHER 1 55 0041216000 PLAIN WASHER 1

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 99

ENGINE & RADIATOR ASSY. S/N3690735~

Engine up to S/N1337562

S/N1337563 to 3690734

Table of Contents

DCA-220SSK — ENGINE & RADIATOR ASSY.

PAGE 100 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Multiquip DCA-220SSK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual