Multiquip DCA-300SSK User Manual

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OPERATION AND PARTS MANUAL

WHISPERWATT

MODELS:

DCA-300SSK DCA-300SSK2 DCA-300SSK3

60 Hz GENERATORS

PARTS LIST NO. C2871300704

SERIAL NO. 3708297~

Revision #4 (03/27/06)

SERIES

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

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

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should

DCA-300SSK SERIES WHISPERWATT AC Generators

. Multiquip Inc. reserves the right to discontinue or change

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

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

TABLE OF CONTENTS

MQPower DCA-300SSKMQPower DCA-300SSK

MQPower DCA-300SSK

MQPower DCA-300SSKMQPower DCA-300SSK SERIES AC GeneratorSERIES AC Generator

SERIES AC Generator

SERIES AC GeneratorSERIES AC Generator

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

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

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ 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:

❒❒

✓FedEx or UPS Ground ✓FedEx or UPS Second Day or Third Day ✓FedEx or UPS Next Day ✓Federal Express Priority One ✓DHL ✓Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

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

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

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

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

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

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

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

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-300SSK SERIES — SPECIFICATIONS

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PAGE 6 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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

Figure 1. Dimensions

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A).mm570,1(.ni23.24F ).mm570,1(.ni23.24

B).mm

C).mm046(.ni02.52H ).mm008,1(.ni89.07

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DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 7

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DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-400SSVU

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

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

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

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

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

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

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

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

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

WARNING - BURN HAZARDS

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

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-300SSK SERIES — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

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

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

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

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

This generator, other property,

NOTE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 9

or the surrounding environment could be damaged if you do not follow instructions.

DCA-300SSK SERIES — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

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

General Safety:

■

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

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

■

This equipment should not be operated by persons under 18 years of age.

■

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

or even

DEATH

! This equipment is to be

DCA-400SSVU Whisperwatt™ AC Generator.

ALWAYS check the machine for loosened threads or bolts

before starting.

■

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

■

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

■

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

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. 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.

bodily harm or even death.

NEVER

operate the generator in any

■

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

■

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

■

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

■

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

■

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

■

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

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

DO NOT leave the generator running in the unattended.

Refer to the technical questions or information.

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

VOLVO Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

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

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

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

The following safety recommendations should also be followed:

To avoid these hazards: NEVER use damaged or worn cables when connecting

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

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

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

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

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

■

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

■

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

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

Backfeed to a utility system can cause

electrocution

and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 11

DCA-400SSVU — RULES FOR SAFE OPERATION

Maintenance Safety

■

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

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

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

■

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

■

Keep the machinery in proper running condition.

■

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

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

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

■

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

■

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

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

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

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

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.

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

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

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

PAGE 12 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-400SSVU — RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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

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

CAUTION - FOLLOW TOWING REGULATIONS

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

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

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

■

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

■

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

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

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

■

Place while parked.

■

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

■

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

■

Avoid sharp turns.

■

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

■

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

■

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

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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

■

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

■

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

■

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

■

DOT Requirements include the following:

z z

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

DCA-300SSK SERIES — GENERATOR DECALS

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

Figure 2. Generator Decals

PAGE 14 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — GENERATOR DECALS

Figure 3. Generator Decals

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 15

DCA-300SSK SERIES — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — INSTALLATION

Outdoor Installation

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

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

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

CAUTION - EXHAUST HAZARD

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

Indoor Installation

Generator Grounding

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

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

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

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

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

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

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

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

Mounting

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

NOTE

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 17

DCA-300SSK SERIES — GENERAL INFORMATION

DCA-300SSK FAMILIARIZATION

Generator

The MQ Power DCA-300SSK series generators are

generators

(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

Tachometer

Throttle Handle (Up to S/N 3701673)

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Warning Display Module

Engine Speed Switch (S/N 3701674~)

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Auto On/Off Engine Controller (S/N 3701674~)

Ignition Switch (Up to S/N 3701673)

Generator Control Panel

The “

Generator Control Panel

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Panel Light

Panel Light Switch

Pilot Lamp

Output Terminal Panel

The “

Output Terminal Panel

3 auxiliary 240/139V output receptacles, 50 amp

3 auxiliary circuit breakers 240V @50 amps

2 120V GFCI receptacles, 20 amp

2 GFCI circuit breakers 120V@ 20amps

Control Box

The “

Control Box

Main Circuit Breaker 800 amps

Over-Current Relay

that are designed as a high quality portable

” is provided with the following:

240 kW

Open Delta Excitation System

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

There are four leads: A, B, C and D. During light loads, the power to the 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.

Engine

The DCA-300SSK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D125E-2 The DCA-300SSK2 and DCA-300SSK3 are powered by a 4 cycle, water cooled, air to air after cooled, turbocharged KOMATSU Model SAA6D125E-2 engines are designed to meet every performance requirement for the generator. Reference Table 2 for engine specifications.

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

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

Electronic Governor System

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

Microprocessor Engine Control (MPEC)

The DCA300SSK3 incorporates the use of a

engine controller

functions and also allows the generator to operate in an unattended mode.

Open-Delta

Automatic Voltage Regulator

" excitation system. The open

(AVR) is supplied

fixed ceiling

diesel

" and responds

diesel

engine.

engine. These

microprocessor

unit (MPEC), which monitors basic engine

PAGE 18 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — MAJOR COMPONENTS

Figure 5. Major Components

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DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 19

DCA-300SSK — GENERATOR CONTROL PANEL

S/N 3701673 and Below

S/N 3701674 and Above

Figure 6. Generator Control Panel

PAGE 20 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the DCA-300SSK

1. Pilot Lamp – Indicates that the generator is working properly.

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

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

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

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

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

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

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

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

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

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

“Control Panel”

major

fault will

(Figure 8).

During engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s " Over Crank Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the "

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

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

B. Low Oil Pressure – Indicates the engine pressure

C. High Coolant Temperature – Indicates the engine

cranking cycle

running of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the 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 position the generator will monitor the AC line output from the building's power source.

has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

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

major

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

, The MPEC will attempt to crank the

Over Speed Protection

manual

fault.

position, the generator will start

" mode.

auto

position. In this

major

fault.

major

fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 21

DCA-300SSK — ENGINE OPERATING PANEL

S/N 3701673 and Below

S/N 3701674 and Above

Figure 7. Engine Operating Panels

PAGE 22 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-300SSK or

Panels”

1. Throttle Handle - This handle controls the speed of

2. Tachometer – Indicates engine speed in RPM’s for 60

3. Engine Warning Display Module – This module

A. Overheat Lamp – This lamp goes ON when

B. Low Oil Pressure Lamp – During normal

C. Low Fuel Level Lamp – When this lamp is

(Figure 7).

the engine (low or high).

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.

display’s the following engine failures:

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.

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

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

DCA-300SSK2

Auto-OFF/Reset

“Engine Operating

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

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

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

7. Fuel Gauge - Indicates amount of diesel fuel available.

8. Pre-Heat Lamp – Indicates that the glow plugs of the

diesel engine are hot and the engine is ready to be started.

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

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

11. Ignition Switch (Up to S/N3701673) – Four position switch, key to start and stop engine.

12. Battery Switch – This switch should be set to the ON position during normal operation. When the engine has been stop, place this switch in the OFF position. DO NOT turn this switch during normal operation, it could cause damage to the electrical equipment.

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

pre-heat, stop, run

and

start

. Insert ignition

D. Low Battery Fluid Lamp – This lamp goes

ON when the battery fluid is low. If this lamp

goes ON during normal operation of the generator, stop the engine and fill the battery with distilled water to the specified level.

E. Clogged Air Filter Lamp – This lamp goes

ON when the air filter is clogged. If this lamp

goes ON during normal operation of the generator, stop the engine and replace the air filter.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 23

DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “

Output Terminal Panel

the following:

Three 240/139V output receptacles, 50 amp

Three circuit breakers 240V @50 amps

Two 120V GFCI receptacles, 20 amp

Two (2) GFCI circuit breakers 120V@ 20 amps

Eight (8) output terminal lugs

” (Figure 8) is provided with

Output Terminal Panel

Shown below (Figure 8) is the up on the cover to gain access to receptacles and terminal lugs.

NOTE

Output Terminal Panel

Terminal legs “O” and “Ground” are considered

bonded grounds

, lift

Figure 8. Output Terminal Panel

PAGE 24 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These

any

receptacles can be accessed in

board

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

Pressing the being tripped. Pressing the " the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

Test Button

voltage change-over

" (See Figure 9) in

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

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Figure 11. Voltage Regulator Control Knob

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

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

Twist Lock Dual Voltage 240/139 VAC Receptacles

There are three 240/139 VAC, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can be accessed in any

voltage change-over board

Figure 10. 240/139 VAC Twist-Lock

Auxiliary Receptacles

position.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 25

DCA-300SSK SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

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

To protect the UVWO output terminals from overload, a 3pole, 800 amp, to switch starting the engine.

main

circuit breaker is provided. Make sure

ALL

circuit breakers to the "OFF" position prior to

Over Current Relay

over current relay

circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the rent relay must be pressed. The over current relay is located in the control box.

(Figure 13) is connected to the main

reset button

Figure 13. Over Current Relay

on the over cur-

Figure 12. Connecting Loads

Maximum Power Output (KW)

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

PAGE 26 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and

Three Phase Load

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

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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's

NOTE

name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

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

WATTS = VOLTAGE x AMPERAGE

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

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

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

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

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

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

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

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

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

If 3Ø load (kVA) is not given on the equipment nameplate,

NOTE

approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

DCA-300SSK SERIES — GENERATOR OUTPUTS

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Generator Output Voltages

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

voltage change-over board

(Figure 14).

Generator Amperage

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

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

(VR)

lator

control knob

located on the control panel.

voltage regu-

Voltage Change-Over Board

The

voltage change-over board

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

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Figure 14. Voltage Change-Over Board 240V Configuration

CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the

change-over board

There exist the possibility of

shock or burn, which can cause severe bodily harm or even death

while the generator is in operation.

electrocution, electrical

voltage

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PAGE 28 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — GENERATOR OUTPUTS/GAUGE READING

Maximum Amps

Table 10 shows the vide. DO NOT exceed the maximum amps as listed.

maximum

amps the generator can pro-

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Change-Over Switch

How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø, 240V operation (See Figure 15), place the

Change-Over Switch

the

AC Ammeter Change-Over Switch

(Figure 16) to the W-U position and

AC Voltmeter

(Figure 18) to the U

Figure 18. AC Ammeter

Change-Over Switch

or W position to read the output on the selected leg.

Figure 17. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 19. AC Ammeter (Amp reading on U lug)

The

NOTE

ammeter

gauges are only active when the

and

voltmeter

UVWO terminals are in use.

Figure 15. Voltage Change-Over Board 240V Configuration

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 29

DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

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

Voltage Change-Over Board Voltage Regulator Control Knob

and the adjustment of the

Figure 22. Voltage Regulator Knob

Remember the voltage change-over board determines the

range

of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected

1Ø-240V UVWO Terminal Output Voltages

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

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

voltage.

3Ø-240V UVWO Terminal Output Voltages

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

Figure 20. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

1Ø-139V UVWO Terminal Output Voltages

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

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

Figure 23. UVWO Terminal Lugs

1Ø-240V Connections

Figure 21. UVWO Terminal Lugs

3Ø-240V Connections

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

PAGE 30 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

Figure 24. UVWO Terminal Lugs

1Ø-139V Connections

DCA-300SSK SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 25. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate

must

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

be used.

Figure 25. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 26.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

Figure 27. UVWO Terminal Lugs

1Ø-480V Connections

NOTE

Figure 26. UVWO Terminal Lugs

3Ø-480V Connections

ALWAYS make sure that the

connections to the UVWO terminals are The possibility of arcing exists, that could cause a fire.

secure

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

Figure 28. UVWO Terminal Lugs

1Ø-277V Connections

and tight.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 31

DCA-300SSK SERIES — PRE-SETUP

Circuit Breakers

Fuel Check

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

main

circuit breaker is provided to protect the UVWO output

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

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

load

circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch

ALL

circuit breakers to

DANGER - EXPLOSION/FIRE HAZARDS

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

the "OFF" position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. Also verify that the oil level is maintained between the two

REFILLING THE FUEL SYSTEM

notches (Figure 29) on the dipstick. See Table 11 for proper selection of engine oil.

The DCA300SSK series generators may (if equipped with a trailer or skid) have a which consists of an

trailer mounted

can be equipped with a The skid type fuel system does not use the internal generator fuel tank.

hot

engine can cause a

double fuel tank system

internal

generator fuel tank, and a

fire

explosion

(Figure 30),

fuel tank. It is also possible the generator

skid mounted

fuel tank (Figure 31).

Figure 29. Engine Oil Dipstick

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

Other types of motor oils may be substituted if they meet the following requirements:

API Service Classification CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

of fuel tank system.

ALWAYS fuel.

DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

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Figure 30. Double Fuel Tank System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

fill the fuel tank with clean and fresh

#2 diesel

PAGE 32 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — PRE-SETUP

CAUTION - REFUELING TRAILER FUEL TANK

Figure 31. Skid Type Fuel Tank System

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity. See Figure 32.

ALWAYS!

filling secondary internal tank.

fill trailer tank

first

with

#2 diesel fuel

, before

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

2. Trailer Fuel Tank First – The trailer fuel tank is the

place trailer on firm level ground before refueling

Figure 32. Only Fill on Level Ground

primary fuel tank and holds a larger capacity of fuel. The fuel in the trailer will be filtered and sent to the engine.

ALWAYS

fill trailer fuel tank (Figure 33) first.

Figure 33. Fuel Tank Filling Order

NOTE

ONLY! use

refueling.

Fuel from the secondary inner tank will eventually drain into the

primary trailer tank.

#2 diesel fuel

when

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 33

DCA-300SSK SERIES — PRE-SETUP

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

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

Figure 34. Full Trailer Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated.

4. Once the trailer tank is full, the

secondary inner tank

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

5. Figure 36 below reflects a full fuel system.

Figure 36. Full Fuel System

Fuel from the engine return line will drain into the secondary

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

WARNING - REFUELING SECONDARY FUEL TANK

It is recommended to only fill the internal secondary fuel tank to 3/4 full in order to allow for fuel return, fuel expansion, and to avoid spillage. See Figure 37 for fuel expansion.

Figure 35. Filling Secondary Internal Fuel Tank

PAGE 34 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

Figure 37. Fuel Expansion

DCA-300SSK SERIES — PRE-SETUP

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

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

NOTE

may become coated with deposits and cooling efficiency will be reduced.

Cleaning the Radiator

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

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

WARNING - BURN HAZARDS

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 11 for engine and radiator, coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

negative

Air Cleaner

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

Fan Belt Tension

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

Komatsu Engine Owner's Manual.

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

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

must be

less than 50%.

battery terminal disconnected.

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Operation Freezing Weather

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

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Figure 38. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 35

DCA-300SSK SERIES — PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified

NOTE

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

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

Always

keep the terminals firmly tightened.

Coating the terminals with an approved battery terminal

CAUTION - BATTERY SERVICING SAFETY

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

treatment compound. Replace battery with only recommended type battery.

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

Battery Cable Installation ALWAYS be sure the battery cables (Figure 39) are properly

connected to the battery terminals as shown below. The

RED

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

CAUTION - BATTERY SERVICING SAFETY

Alternator

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

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

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

Wiring

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

ALWAYS

disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

(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 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.

If any hose (

immediately

If applicable perform the following:

Figure 39. Battery Connections

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the

ignition

switch is in either the Pre-

Heat, RUN, or START position. ALWAYS make sure

that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment

■

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

option

■

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

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

PAGE 36 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

fuel

option

oil

) lines are defective replace them

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

BEFORE STARTING (S/N 3701673 and below)

Steps 1 thru 20 are referenced

NOTE

Figure 40. Engine Operating Panel S/N 3701673 and Below

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

for Engine Operating Panel S/N 3701673 and below. See Figure 40 below. This unit has an

switch

tion handle

and a

igni-

throttle

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

1. Place the in the “OFF” position prior to starting the engine.

2. Make sure the the been configured for the desired output voltage.

3. Connect the load to the

receptacles

connection points can be found on the output terminal panel. To gain access to the UVWO terminals or other power receptacles, unlock the access cover and lift the door.

4. Tighten terminal nuts securely to prevent load wires from

slipping out

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

main, G.F.C.I.

Figure 42. Main, Aux. and GFCI

Circuit Breakers (OFF)

and

aux.

circuit

breakers (Figure 42)

voltage change-over board

UVWO

as shown in Figure 12. These load

terminals or

has

auxiliary

WARNING - STARTING THE GENERATOR

NEVER!

manually start the engine with the

auxiliary

circuit breakers in the ON (closed) position.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 37

main, GFCI

Figure 42. Engine Enclosure Doors

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

6. Set the position.

battery ON/OFF switch

Figure 43. Battery ON/OFF Switch

(Figure 43) to the “ON”

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

7. When starting the generator in COLD weather conditions, turn the

ignition key

to the “PREHEAT ” position (Figure 44).

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

Figure 44. Ignition Switch (Pre-Heat)

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

Figure 48. Frequency Meter (Hz)

Pre-Heat

Button

Figure 45. Pre-Heat Button/ Lamp

9. Place the

engine throttle control

in the “LOW” position

Pre-Heat

Lamp

(Figure 46).

Figure 46. Engine Throttle Control

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

Figure 47 Engine Ignition Switch

Figure 49. Voltmeter

Figure 50. Voltage Adjust Control Knob

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

Figure 51. Ammeter (No Load)

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

PAGE 38 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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

15. The engine oil pressure gauge (Figure 52) will indicate the oil pressure (kg/ cm

of the engine. Under normal

18. Place the “ON” position (Figure 55).

operating conditions the oil pressure is approximately

kg/cm2

ENGINE OIL PRESSURE

Figure 52. Oil Pressure Gauge

16. The

coolant temperature gauge

(Figure 53) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit (

Green Zone

19. Observe the generator's ammeter (Figure 56) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current

WATER

TEMP

reading if a load is in use.

main, GFCI

, and

aux

. circuit breakers in the

Figure 55. Main, Aux. and GFCI

Circuit Breakers (ON)

Figure 53. Coolant Temperature Gauge

17. The

tachometer gauge

(Figure 54) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 54. Engine Tachometer Gauge

Figure 56. Ammeter (Load)

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 39

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

BEFORE STARTING (S/N 3701674 and above)

Steps 1 thru 8 are referenced for Engine Operating Panel

NOTE

S/N 3701674 and above. See Figure 57 below. This unit does not have an ignition switch or a throttle handle. It does have an “

engine speed switch

used in conjunction with the MPEC unit.

Figure 57. Engine Operating Panel

S/N 3701674 and Above

” that is

4. Place the engine speed switch in the “ (Figure 60)

Figure 60. Engine Speed Switch (Low)

5. Place the Auto-Off/Reset-Manual switch in the “

LOW

” position

Manual”

position to start the engine (Figure 61). Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 61. Auto-Off/Reset-Manual Switch

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

HIGH

” position

(Figure 62).

1. Before attempting to start generator, reference steps 1 thru 5 in the “ Operating Panel S/N 3701673 and below.

2. Set the

battery ON/OFF switch

position.

Figure 58. Battery ON/OFF Switch

Before Starting Section

” for Engine

(Figure 58) to the “ON”

Figure 62. Engine Speed Switch (High)

7. Verify that the "Engine Running" status LED on the MPEC

unit (Figure 63) is "ON" (lit) after the engine has been started.

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

Figure 63. Engine Running LED (ON)

Pre-Heat

Button

Pre-Heat

Lamp

8. Continue operating the generator as outlined in steps 11 thru 20 in the “ Operating Panel S/N 3701673 and below.

Figure 59. Pre-Heat Button/ Lamp

Before Starting Section

” for Engine

PAGE 40 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

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

electrician (transfer) switch

building’s electrical system may occur without this transfer switch.

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.

NOTE

must install an

. Serious damage to the

CAUTION - BACKUP GENERATOR USE

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

licensed

isolation

in the event of

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Before attempting to start generator, reference steps 1 thru 5 in the “ Operating Panel S/N 3701673 and below.

2. Set the position.

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

4. Place the Off/Manual/Auto switch (Figure 66) on the MPEC unit to the AUTO position.

Before Starting Section

battery ON/OFF switch

Figure 64. Battery ON/OFF Switch

Figure 65. Engine Speed Switch (High)

(Figure 64) to the “ON”

” for Engine

Manual

WARNING - AUTO MODE MAINTENANCE

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

CAUTION - ENGINE SPEED SWITCH

The

Engine Speed Switch

position when running in the set the switch in the proper position can result in damage to your generator when it turns on.

NOTE

must be set to the “High”

Auto-Start

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

mode. Failing to

Control Switch

Figure 66. Off/Manual Auto Switch (AUTO)

5. Continue operating the generator as outlined in steps 11 thru 19 in the “ Operating Panel S/N 3701673 and below.

Before Starting Section

” for Engine

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 41

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

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

To shutdown the generator use the following procedure:

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

Engine Shutdown Controller (S/N 3701674~)

To shutdown the generator use the following procedure:

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

(Figure 67) to the "OFF position".

2. Place the engine speed switch in the “

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

Figure 67. Main, Aux. and GFCI

Circuit Breakers (OFF)

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

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

as shown in Figure 67 to the "OFF position".

LOW

(Figure 71).

Figure 71. Engine Speed Switch (High)

load applied.

the

OFF/Reset

position.

” position

Figure 68. Engine Throttle Control

Figure 72. Auto-Manual Off/Reset Switch

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

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

5. Verify that the "OFF" (not lit).

6. Remove all loads from the generator.

Figure 69. Ignition Key Switch (STOP position)

5. Remove all loads from the generator.

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

Emergency Shutdown Procedure

used in the event of an emergency.

1. PUSH inward the RED emergency stop button located on the

engine operating panel

(Figure 70) to turn off the generator in the event of an emergency. This button is located on either Engine Operating Panel.

NOTE

generator will not start if the emergency stop button is engaged.

Figure 70. Emergency Stop Button

all

WARNING -

SHUTTING DOWN THE GENERATOR

status LED on the MPEC display are

To disengage the emergency stop function, pull the emergency stop button outward to its original position. This will allow the generator to operate normally. Remember the

PAGE 42 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

NOTE PAGE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 43

DCA-300SSK SERIES — MAINTENANCE

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

ECNANETNIAM/NOITCEPSNI.31ELBAT

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straPfogninesooLrofkcehC X

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ENIGNE

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edistuOdnaedisnI,tinUnaelC X

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tnemelEretliFriAecalpeR X

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PAGE 44 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — MAINTENANCE

General Inspection

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

Air Cleaner

Every

50 hours

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.

: If dust indicator is RED, clean the air cleaner

Fuel Addition

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

Removing Water from the Tank

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

Air Removal

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

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

Service Daily

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

Cleaning the Fuel Strainer

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.

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

Check Oil Level

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

Check Electric Heater (If equipped)

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 45

DCA-300SSK SERIES — MAINTENANCE DCA-300SSK SERIES — MAINTENANCE

WARNING - BURN HAZARDS

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

Flushing Out Radiator and Changing Coolant

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

2. Turn water filer cap slowly and remove it.

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

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

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

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

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

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

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

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

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

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

cool

when flushing out

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.

Changing Oil

1. Make sure the oil is cool before changing.

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

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

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

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

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

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

Replacing Fuel Filter

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

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

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

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

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

PAGE 46 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES — MAINTENANCE

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

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

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

8. Replace Corrosion resistor cartridge (if equipped)

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

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

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

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

13. Open valves.

Cleaning Breather Element

Generator Storage:

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

Fill the fuel tank completely. Treat with fuel stabilizer if necessary.

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

Clean the entire generator, internal and external.

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

If the ambient temperature is expected to drop below

C, add antifreeze to the radiator.

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

Removal From Long Term Storage:

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

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

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

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

Greasing

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

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

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.

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 47

DCA-300SSK SERIES — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

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

The purpose of these receptacles is to provide power via commercial power to the

battery charger

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

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

jacket water heate

hot

climates there is no reason

cold

climates it is always a good

r and i

nternal

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

NOTE

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

internal battery charger

Figure 73. Battery Charger/Jacket Water

Heater Power Connections

PAGE 48 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES —TRAILER MAINTENANCE

Trailer Maintenance

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

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

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

Whisperwatt

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

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

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

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

5. Frame Width - Measurement is from fender to fender

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

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

™

Generator.

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

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

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

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

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 64 and sequence.

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

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

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

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

for lug nut tightening

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 49

DCA-300SSK SERIES —TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

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

Hydraulic Surge Brakes

Hydraulic surge brakes should not require any special

attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 74 displays the major hydraulic surge brake

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

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate the

Figure 74. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

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

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

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

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

Actuator

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

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

surge

actuator

” to make

push

gnitoohselbuorTekarBciluardyH.41elbaT

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

?dezalggninilekarB.ecalperrohsinrubeR

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

opmocekarB.stnenopmocecalpeR

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserperiT.yllauqeseritllaetalfnI

?elxaemasehtnodehctamnuseriT.serithctaM

?nekorbrotneb,esoolstnen

?dnuor-fo-tuosmurdekarB.ecalpeR

?detacirbulmetsyS.etacirbuL

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

tonrotcerrocnissenkcihtgninilekarB

?yltcerrocdetsujda

?diulftcerrocrodiulfekarbhguonEstraprebburecalpeR

dnaseohswenllatsnI

.sgninil

.diulf4todhtiwllif

PAGE 50 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK SERIES —TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

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

Suspension

The

leaf suspension

(Figure 75) should be visually inspected for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 16.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

springs and associated components

every 6,000

miles

Figure 75. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

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

SHACKLE BOLT SPRING EYE BOLT

SHOULDER TYPE SHACKLE BOLT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY.PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT

BOLT ASSEMBLY

stnemeriuqeReuqroTnoisnepsuS.61elbaT

05-XAM03-NIM

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 51

DCA-300SSK SERIES —TRAILER MAINTENANCE

Lug Nut Torque Requirements

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

1. Start all wheel lug nuts by hand.

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

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

stnemeriuqeReuqroTeriT.71elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 76. Wheel Lug Nuts Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

NOTE

Use a

torque wrench

lug nuts.

PAGE 52 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

to tighten

DCA-300SSK — TRAILER-WIRING DIAGRAM

Figure 77. Trailer/Towing Vehicle Wiring Diagram

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 53

DCA-300SSK — GENERATOR WIRING DIAGRAM

Figure 78. Generator Wiring Diagram

PAGE 54 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 55

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

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

PAGE 56 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

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

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

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 57

DCA-300SSK — TROUBLESHOOTING (ENGINE)

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

GNITOOHSELBUORTENIGNE.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

?erutarepmet

woltalioenigneroleuf

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

?tungniniaterepip

tratstonseodenignE

?nrowtfahsmacleuF .ecalpeR

?rednilyc

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?degrahcsidyrettaB .yrettabegrahC

noitcejniesooloteudkaelleuF

?gnimitnoitcejnitcerrocnI .tsujdA

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.tunnethgiT

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?gninoitcnuflamretratS .ecalperroriapeR

.nurtonseodretratS

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

PAGE 58 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.81ELBAT

?tungniniaterepip

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

.tunnethgiT

tonsinoituloverenignE

.htooms

?erusserp

?deggolc

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?desuleufedargwoL .leufdeificepsehtesU

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 59

DCA-300SSK — TROUBLESHOOTING (GENERATOR)

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

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

deppirTrekaerBtiucriC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?daolnitiucriCtrohS .riaperdnadaolkcehC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 60 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK — TROUBLESHOOTING (ENGNE CONTROLLER)

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

thgilerusserpliowoL

.nosi

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

.nosi

tnaloochgiH

thgilleveltnaloocwo

.nosithgilerutrepmet

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yretta

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytlu

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplio

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaida

rhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

ecalpeR

begrahc/ecalpeR

afrosteksagriaper/ecalpeR

?leuFwolrooN.levelleuflliF

evO

ssoL

.no

.nosithgilknarcr

?detarbilacebotsdeenrellortnoC.relaedotrefeR

psenigneMPR.MPRtsujdA

.nosithgildeepsrevO

tnocronrevoG .rellortnocronrevogtsujdA

ro)s(thgilUPMfo

?hgihootdee

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellor

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipcitengaM .pukcipcitengamnaelC

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 61

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1.... INCLUDES ITEMS W/

12347 WASHER, 3/8 IN. .... 1 ....

3 12348 HOSE .................... A/R .. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

, #, +, %, or >) in the number column belong to the same

(

assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTE

without notice

WASHER, 1/4 IN. ...........

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

QTY. Column

Numbers Used - Item quantity can be indicated by a number,

a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts

that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold

separately. Other entries will be clarified in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit

symbol will be included when this item is purchased. Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

range where a particular part is used. Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

PART NO. Column

Numbers Used - Part numbers can be indicated by a number,

a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part

that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

PAGE 62 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-300SSK — SUGGESTED SPARE PARTS

DCA-300SSK W/KOMATSU SA6D125E-2/ SAA6D125E-2

1 to 5 Units

Qty. P/N Description

10 .............. 6125817032 .....................AIR FILTER, INNER & OUTER

10 .............. 6003118321 .....................FUEL FILTER

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

5 ................ 6004111151 .....................CARTRIDGE, CORROSION RESISTOR

3 ................ 0810105400 .....................FUEL FILTER, FUEL TANK

2 ................ xxxxxxxxxx ..................... ENGINE FAN BELT

1 ................ 6008155390 .....................SWITCH, STARTER................................. UP TO S/N 370163

5 ................ 615 ................................... KEY SET, STARTER SWITCH (2) ........... UP TO S/N 370163

1 ................ 6152611520 .....................RADIATOR HOSE (UPPER)..................... UP TO S/N 3708296

1 ................ 6152611531 .....................RADIATOR HOSE (LOWER) .................... UP TO S/N 3708296

1 ................ 6152611530 .....................RADIATOR HOSE (UPPER)..................... S/N 3708297 AND ABOVE

1 ................ 6152621540 .....................RADIATOR HOSE (LOWER) .................... S/N 3708297AND ABOVE

1 ................ 0605505030 .....................FUEL CAP

1 ................ 0601850590 .....................KEY, FUEL CAP

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

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

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

1 ................ 23S0311150M ..................CAP, RADIATOR ...................................... UP TO S/N 3708296

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

1 ................ 0602123206 .....................UNIT, WATER TEMPERATURE

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

1 ................ 0601804887 .....................CIRCUIT BREAKER, OUTPUT

............................................................TERMINAL,KM51, 265V 20A ................... UP TO S/N 3706720

1 ................ 0601808803 .....................CIRCUIT BREAKER, OUTPUT

............................................................TERMINAL,QOU120B 20A ...................... TO S/N 3706721 ABOVE

1 ................ 0601805840 .....................CIRCUIT BREAKER, OUTPUT

............................................................TERMINAL,KM52, 265V 50A ................... UP TO S/N 3706720

1 ................ 0601808804 .....................CIRCUIT BREAKER, OUTPUT

............................................................TERMINAL,QOU250B 50A ...................... TO S/N 3706721 ABOVE

Part number on this Suggested Spare Parts

NOTE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 63

list may supercede/replace the P/N shown in the text pages of this book.

GENERATOR ASSY.

DCA-300SSK GENERATOR ASSY.

PAGE 64 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2110100302 ROTOR ASSY. ............................................... 1 ......... INCLUDES ITEM W/

3 4 5 5 5 6 7 8 9 10 11 12 13 14 15 8201614003 COUPLING RING 1 16 0012116040 HEX. HEAD BOLT 6 17 0042516000 LOCK WASHER 6 18 0012112040 HEX. HEAD BOLT 12 18 0042512000 LOCK WASHER 12 19 C2130100103 STATOR ASSY. 1 20 0226200430 RUBBER SEAL 1 21 8201323004 CLAMPER 1 22 0223300140 RUBBER SEAL 1 23 8201323103 CLAMPER 1 24 0221200350 RUBBER SEAL 1 25 0010110035 HEX. HEAD BOX 2 25 0041210000 PLAIN WASHER 2 26 C2132200003 COVER 1 27 0226000275 RUBBER SEAL 2 28 0225000500 RUBBER SEAL 1 29 0017106016 HEX. HEAD BOLT 6 30 0601850144 GROMMET 1 31 C3154000002 END BRACKET 1 32 C3138000003 FIELD ASSY. EXCITER 1 33 0012110080 HEX. HEAD BOLT 4 33 0042610000 LOCK WASHER 4 33 0041210000 PLAIN WASHER 4 34 0017112045 HEX. HEAD BOLT 8 35 C3154300104 COVER, BEARING 1 36 C3154300004 GASKET, BEARING 1 37 0010106060 HEX. HEAD BOLT 4 37 0040006000 LOCK WASHER 4 37 0041206000 PLAIN WASHER 4

0601842401 RESISTOR ...................................................... 2 ......... 80W 300K OHM

0601823282 RECTIFIER ..................................................... 1 ......... RM50TC-24

0018205020 HEX. SOCKET HEAD CAP SCREW 2

0040005000 LOCK WASHER 2

0041205000 PLAIN WASHER 2

8201070002 FAN 1

8201611004 COUPLING DISK 12

C3164200004 WASHER, COUPLING HUD 1

8201015003 BALANCING PLATE ....................................... 1 ......... PURCHASE AS SET OF 1-14

0012116045 HEX. HEAD BOLT 10

0042616000 LOCK WASHER 10

0601000209 BALANCING WEIGHT KIT 1

C3112500004 BEARING FLANGE 1

0071906315 BEARING ........................................................ 1 ......... 6315DDUC3

FIELD ASSY. 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 65

GENERATOR ASSY.

DCA-300SSK GENERATOR ASSY.

PAGE 66 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK GENERATOR ASSY.

GENERATOR ASSY.(CONT)

NO. PART NO. PART NAME QTY. REMARKS

38 C3154400003 SUCTION COVER 1 39 0017106016 HEX. HEAD BOLT 8 40 0012112035 HEX. HEAD BOLT 16 40 0042512000 LOCK WASHER 16

41 C3132300003 COVER, FAN ................................................... 1 ......... S/N3691259 TO 3692208

41 C3132300014 COVER, FAN ................................................... 1 ......... S/N3692209 AND ABOVE

42 0010106030 HEX. HEAD BOLT 1 42 0041206000 PLAIN WASHER 1

42 0600815000 NUT ................................................................. 1 ......... S/N3692209 AND ABOVE

43 0605000012 RUBBER SUSPENSION 2 44 0030020000 HEX. NUT 4 44 0040020000 LOCK WASHER 4

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 67

CONTROL BOX ASSY.

DCA-300SSK CONTROL BOX ASSY.

PAGE 68 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2214000102 CONTROL BOX .............................................. 1 ............... S/N 3691259 TO 3706720

1 C2214001502 CONTROL BOX .............................................. 1 ............... S/N 3706721 AND ABOVE

2 0601806134 CURRENT TRANSFORMER .......................... 3 ............... CT-5MR500/5A

3 0027106016 MACHINE SCREW 6

4 0601807373 CIRCUIT BREAKER,XS800NS800A .............. 1 ............... UP TO 3706720

4 0601807513 CIRCUIT BREAKER, S6G800A...................... 1 ............... S/N 3706721AND ABOVE

5 0601802525 HANDLE, CIRCUIT BREAKER....................... 1 ............... S/N 3691259 TO 3706720

6 C2214600004 BRACKET, CIRCUIT BREAKER .................... 2 ............... S/N 3691259 TO 3706720

6 C2261600204 BRACKET, CIRCUIT BREAKER .................... 1 ............... S/N 3706721AND ABOVE

7 0017108020 HEX. HEAD BOLT 4 8 0021008045 MACHINE SCREW 4

8 0030008000 HEX. NUT ....................................................... 4 ............... S/N 3691259 TO 3706720

8 0040008000 LOCK WASHER .............................................. 4 ............... S/N 3691259 TO 3706720

8 0041208000 PLAIN WASHER ............................................. 4 ............... S/N 3691259 TO 3706720

9 0601820625 AUTOMATIC VOLTAGE REGULATOR ............. 1 ............... NTA-5A-2T

10 0027105016 MACHINE SCREW 4

11 0601820892 OVER CURRENT RELAY ............................... 1 ............... TH-N20HZKP

12 0027104016 MACHINE SCREW 2 13 C2274000103 CHANGE-OVER BOARD VOLTAGE 1 14 8201852104 CHANGE TERMINAL 10 15 0017108030 HEX. HEAD BOLT 20 16 C2277200004 TERMINAL PLATE 3 17 8201853104 CHANGE PLATE 6 18 8201852504 HEX. HEAD BOLT 13 19 0801830704 HEX. HEAD BOLT 13 20 0040012000 LOCK WASHER 26 21 0041412000 PLAIN WASHER 26 22 0017110030 HEX. HEAD BOLT 4

23 C2261500003 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 1337508 TO 3691258

23 C2261500013 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 3691259 TO 3696506

23 C2261500703 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 3696507 TO 3701673

23 C2261500713 SET PANEL, ELECTRIC PARTS .................... 1 ............... S/N 3701674 AND ABOVE

24 0017108020 HEX. HEAD BOLT .......................................... 4

25 6008151252 EMERGENCY RELAY .................................... 1 .............. S/N 3696507 TO 3701673

......................................................................................... REPLACES 0602200446

26 0017106016 HEX. HEAD BOLT .......................................... 4 .............. S/N 3696507 TO 3701673

27 0601824542 RELAY ............................................................ 2 .............. HH62SDC24V

28 0027103010 MACHINE SCREW ......................................... 4

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 69

CONTROL BOX ASSY. (CONT)

DCA-300SSK CONTROL BOX ASSY.

PAGE 70 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK CONTROL BOX ASSY.

CONTROL BOX ASSY. (CONT)

NO. PART NO. PART NAME QTY. REMARKS

29 0602201911 UNIT, BATTERY SENSOR ..........................1 ........ C7038A-00-00

30 0027106016 MACHINE SCREW 1 31 C2224000503 CONTROL PANEL 1

32 C2224000404 CONTROL PANEL ......................................1 ........ S/N3691259 TO 3706720

32 C2224001504 CONTROL PANEL ......................................1 ........ S/N3706721 AND ABOVE

33 0605011211 PIN 2

34 0601807622 FREQUENCY METER ................................1 ........ RSC-80F 220V 45-65HZ

35 0601806979 AC AMMETER ...........................................1 ........ RSS-80 0-500A 0-1000A

36 0601801040 CHANGE-OVER SWITCH, AMMETER ...... 1 ........ SL-2AS

37 0601806887 AC VOLTMETER ........................................ 1 ........ RSR-80 0-600V

38 0601801041 CHANGE-OVER SWITCH, VOLTMETER ...1 ........ SL-2VS

39 0601810072 PILOT LAMP .............................................. 1 ........ LP-132DC 220V

39 0601810261 BULB ..........................................................1 ........ CT-13W

40 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ........1 ........ RA20A2SE102BJ 2W 1K OHM

41 0601840121 KNOB 1

42 0601810161 PANEL LIGHT .............................................1 ........ V325070

42 0601810214 BULB 1 43 0207004000 HEX. NUT 2 44 0601830710 SWITCH, PANEL LIGHT 1

45 C2214600104 COVER ....................................................... 1 ........ S/N3691259 TO 3706720

46 0027105016 MACHINE SCREW .....................................4 ........ S/N3691259 TO 3706720

47 C9221100004 HEX. HEAD BOLT 2 47 0040008000 LOCK WASHER 2 47 0041208000 PLAIN WASHER 2

47 505015300 SNAP RING ................................................2 ........ REPLACES 0080200007

48 0017108040 HEX. HEAD BOLT 4 49 3871824004 STOPPER, CONTROL PANEL 1 50 0041206000 PLAIN WASHER 1 51 0605010502 SNAP PIN 1 52 C2214500004 COVER, CONTROL BOX 1 53 0017108020 HEX. HEAD BOLT 8 54 C2214300004 SIDE PANEL, CONTROL BOX 1 55 0017108020 HEX. HEAD BOLT 4 56 C2214400004 PANEL, CONTROL BOX 1 57 0017108020 HEX. HEAD BOLT 8 58 0017110025 HEX. HEAD BOLT 4

59 0601823861 ENGINE STOP UNIT, MSA9014 .................1 ........ S/N3696507 TO 3701673

60 0027104015 MACHINE SCREW .....................................2 ........ S/N3696507 TO 3701673

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 71

CONTROL BOX ASSY. (CONT)

DCA-300SSK CONTROL BOX ASSY.

PAGE 72 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK CONTROL BOX ASSY.

CONTROL BOX ASSY. (CONT)

NO. PART NO. PART NAME QTY. REMARKS

61 0601823240 RECTIFIER, DE4503 ..................... 4 .............. S/N 3696507 TO 3701673

62 0021004030 MACHINE SCREW ........................ 2 .............. S/N 3696507 TO 3701673

62 0040004000 LOCK WASHER ............................. 2 .............. S/N 3696507 TO 3701673

62 0041204000 PLAIN WASHER ............................ 2 .............. S/N 3696507 TO 3701673

63 0601802149 FUSE, 10A ..................................... 1 .............. S/N 3696507 TO 3701673

63 0601802149 FUSE (RIGHT), 10A ...................... 1 .............. S/N 3701674 AND ABOVE

63 0601806671 FUSE (LEFT), 15A ......................... 1 .............. S/N 3701674 AND ABOVE

63 0601802218 HOLDER, FUSE ............................ 1 .............. S/N 3701674 AND ABOVE

64 0027103020 MACHINE SCREW ........................ 2 .............. S/N 3701674 AND ABOVE

65 0601823732 RELAY ........................................... 1 .............. S/N 3696507 TO 3699681

65 0601827655 RELAY ........................................... 1 .............. S/N 3699682 AND ABOVE

65 0601823109 SOCKET ........................................ 1 .............. S/N 3696507 AND ABOVE

65 0601824400 HOLDER ........................................ 1 .............. S/N 3696507 AND ABOVE

66 0027104020 MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE

67 0601823706 RELAY, HE1ADC24V ..................... 1 .............. S/N 3696507 AND ABOVE

68 0027104015 MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE

69 0601815402 TERMINAL BOARD, TS144P......... 1 .............. S/N 3696507 AND ABOVE

70 0027104020 MACHINE SCREW ........................ 2 .............. S/N 3696507 AND ABOVE

71 ECU9988N300/400 CONTROLLER ............................... 1 .............. REPLACES 0601827396 & 0602202545

72 0601831340 SWITCH, 82608DPDT ................... 1 .............. S/N 3696507 TO 3700240

72 0601830765 SWITCH, S303T ............................ 1 .............. S/N 3700241 AND ABOVE

73 DYNT11200 SPEED SENSOR .......................... 1 .............. S/N 3696507 AND ABOVE

73 0602202470 SEALED CABLE ............................ 1 .............. S/N 3696507 AND ABOVE

74 DYN110654000024 CONTROLLER ............................... 1 .............. S/N 3701674~; REPLACES 0602202598

75 0027104020 MACHINE SCREW ........................ 4 .............. S/N 3701674 ABOVE

76 0601840009 RHEOSTAT, RA20A2SE5028 ......... 1 .............. S/N 3701674 ABOVE

77 C3262600004 BRACKET ...................................... 1 .............. S/N 3701674 ABOVE

78 0017106015 HEX. HEAD BOLT ......................... 2 .............. S/N 3701674 ABOVE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 73

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

PAGE 74 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

ENGINE & RADIATOR ASSY. (S/N 3697258 AND BELOW)

NO. PART NO. PART NAME QTY. REMARKS

1 6155009100 ENGINE, KOMATSU SA6D 125E-2 .............. 1 ..........S/N 3691258 AND BELOW

....................................................................................REPLACES C2924200014

2 6125817032 ELEMENT, AIR CLEANER ............................ 1 ..........REPLACES 0602040156

3 6002111231 CARTRIDGE, OIL FILTER ............................ 1 ..........REPLACES 0602041146

4 6003118293 CARTRIDGE, FUEL FILTER ......................... 1 ..........REPLACES 0602042146

5 6004111151 CARTRIDGE, CORROSION RESISTOR ...... 1 ..........REPLACES 0602045143

6 0602040678 DUST SENSOR ............................................ 1 ..........REX01-8126

7 8185112004 ENGINE FOOT .............................................. 1 ..........S/N 3691258 AND BELOW

8 0010118060 HEX. HEAD BOLT ......................................... 2 ..........S/N 3691258 AND BELOW

9 0030018000 HEX. NUT ..................................................... 2 ..........S/N 3691258 AND BELOW

10 0040018000 LOCK WASHER ............................................ 2 ..........S/N 3691258 AND BELOW

11 0041218000 PLAIN WASHER ........................................... 4 ..........S/N 3691258 AND BELOW

12 0605000011 RUBBER SUSPENSION 2 13 0030016000 HEX. NUT 4 14 0040016000 LOCK WASHER 4

15 6152619720 RADIATOR .................................................... 1 ..........REPLACES 0602011946

16 6152619170 RUBBER SHEET .......................................... 2 .......... REPLACES 0605000490

17 0010012055 HEX. HEAD BOLT 4 18 0030012000 HEX. NUT 4 19 0040012000 LOCK WASHER 4 20 0041212000 PLAIN WASHER 8 21 8195123104 BRACKET, RADIATOR 2 22 0017112025 HEX. HEAD BOLT 2 23 0017110025 HEX. HEAD BOLT 2

24 6152611520 RADIATOR HOSE ......................................... 1 ..........REPLACES 0602014513

25 6152611531 RADIATOR HOSE ......................................... 1 ..........REPLACES 0602014641

26 0726120911 RADIATOR HOSE ......................................... 1 ..........REPLACES 0602014541

27 0728100809 HOSE BAND ................................................. 6 ..........REPLACES 0602014067

28 0728100909 HOSE BAND ................................................. 2 ..........REPLACES 0602014056

29 0728001920 HOSE BAND ................................................. 2 ..........REPLACES 0602014058

30 0802081003C RESERVE TANK ........................................... 1 ..........REPLACES 0802081003

31 0802010900 CAP, RESERVE TANK .................................. 1 ..........REPLACES 0602010900

32 C231710003 BRACKET, RESERVE TANK 1 33 0017108020 HEX. HEAD BOLT 2 34 0199601800 HOSE 1 35 0193601300 HOSE 1 36 0193600500 HOSE 1 37 0194100800 HOSE 1 38 0605515170 HOSE BAND 5 39 C2327100003 BREATHER PIPE 1 40 0017108020 HEX. HEAD BOLT 2

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 75

DCA-300SSK ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

PAGE 76 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

ENGINE & RADIATOR ASSY. (UP TO S/N3697258)

NO. PART NO. PART NAME QTY. REMARKS

41 0603320112 U BOLT 1 42 0038408000 HEX. NUT 2 43 0268200700 HOSE 1 44 0605515132 HOSE BAND 2 45 C2358300103 CLAMPER ROD 1 46 0017110020 HEX. HEAD BOLT 2 47 C2358300003 CLAMPER ROD 1 48 0017108020 HEX. HEAD BOLT 1 49 0010016030 HEX. HEAD BOLT 1 50 0040016000 LOCK WASHER 1 51 0041216000 PLAIN WASHER 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 77

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 TO 3708296)

ENGINE & RADIATOR ASSY. (S/N3691259 TO S/N 3708296)

PAGE 78 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 TO 3708296)

ENGINE & RADIATOR ASSY. (S/N3691259 TO S/N 3708296)

NO. PART NO. PART NAME QTY. REMARKS

1 C2924200154 ENGINE ................................................................. 1 .......... REPLACES S/N 3691259 TO 3701673

1 C2925200014 ENGINE ................................................................. 1 .......... S/N3701674 TO 3708269

2 6125817032 ELEMENT, AIR CLEANER, INNER/OUTER 1 3 6002111231 CARTRIDGE, OIL FILTER 1 4 6003118321 CARTRIDGE, FUEL FILTER 1 5 6004111151 CARTRIDGE, CORROSION RESISTOR 1

6 0602040678 DUST SENSOR ..................................................... 1 .......... REX018126

7 0605000011 RUBBER SUSPENSION ....................................... 2 .......... EA1012

8 0030016000 HEX. NUT 4 9 0040016000 LOCK WASHER 4

10 6152619720 RADIATOR............................................................. 1 .......... REPLACES 0602011946

11 615261970 RUBBER SHEET ................................................... 2 .......... REPLACES 0605000490

12 0010112055 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 0602014549 RADIATOR HOSE ................................................. 1 .......... REPLACES 6152611520

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

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

22 0728100809 HOSE BAND .......................................................... 6 .......... REPLACES 0602014056

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

25 0802081003 RESERVE TANK 1 26 0602010900 CAP, RESERVE TANK 1 27 C2317100003 BRACKET, RESERVE TANK 1 28 0017108020 HEX. HEAD BOLT 2 29 0199901800 HOSE 1 30 0193601300 HOSE 1 31 0193600500 HOSE 1 32 0194100800 HOSE 1 33 0605515170 HOSE BAND 5

34 C2327100003 BREATHER PIPE ................................................... 1 .......... S/N3691259 TO 3705209

34 C2327100012 BREATHER PIPE ................................................... 1 .......... S/N3705210 TO 3708269

35 0017108020 HEX. HEAD BOLT 2 36 0603320112 U BOLT 1 37 0207008000 HEX. NUT 2 38 0268200700 HOSE 1 39 0605515132 HOSE BAND 2 40 C2358300103 CLAMPER ROD 1 41 0017110020 HEX. HEAD BOLT 2 42 C2358300003 CLAMPER ROD 1 43 0017108020 HEX. HEAD BOLT 1 44 0010016030 HEX. HEAD BOLT 1 45 0040016000 LOCK WASHER 1 46 0041216000 PLAIN WASHER 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 79

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

PAGE 80 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

NO. PART NO. PART NAME QTY. REMARKS

1 C2924200194 ENGINE ............................................................. 1 .......... KOMATSU SAA6D125E-2

1-1 6125817032 ELEMENT, AIR CLEANER ................................. 1 .......... REPLACES 06020 40145

1-2 6002111231 CARTRIDGE, OIL FILTER ................................. 1 .......... REPLACES 06020 41146

1-3 6003118321 CARTRIDGE, FUEL FILTER .............................. 1 .......... REPLACES 06020 42146

1-4 6004111151 CARTRIDGE, COROSION RESISTOR ............. 1 .......... REPLACES 06020 45143

1-5 0602040678 SENSOR, DUST REX01-8126 1 2 0605000011 SUSPENSION, RUBBER EA1012 2 3 0030016000 NUT, HEX 4 4 0040016000 WASHER, SPRING 4

5 6152629101 RADIATOR ........................................................ 1 .......... REPLACES 06020 12706

6 6995619230 SHEET, RUBBER............................................... 2 ..........REPLACES 06050 00085

7 0010120070 BOLT, HEX HEAD 4 8 0030020000 NUT, HEX 8 9 004002000 WASHER, SPRING 4 10 0041220000 WASHER, PLAIN 8 11 C2311100504 BRACKET, RADIATOR 2 12 0010112025 BOLT, HEX HEAD 2 13 0040012000 WASHER, SPRING 2 14 0041212000 WASHER, PLAIN 2 15 0017110025 BOLT, HEX HEAD 2

16 6152611530 HOSE, RADIATOR............................................. 1 .......... REPLACES 06020 14539

17 6125621540 HOSE, RADIATOR............................................. 1 .......... REPLACES 06020 14653

18 0726120911 HOSE, RADIATOR............................................. 1 .......... REPLACES 06020 14541

19 0728100809 HOSE BAND ...................................................... 6 .......... REPLACES 06020 14067

20 0728100909 HOSE BAND ...................................................... 2 .......... REPLACES 06020 14056

21 0728100197 HOSE BAND ...................................................... 2 .......... REPLACES 06020 14058

22 6152124380 PIPE, RADIATOR ............................................... 1 .......... REPLACES 06020 13257

23 6152124410 HOSE, RADIATOR............................................. 2 .......... REPLACES 06020 14578

24 6152124420 HOSE, RADIATOR............................................. 1 .......... REPLACES 06020 14579

25 0602014900 HOSE BAND ...................................................... 8 .......... REPLACES 06020 14900

26 6152124490 HOSE BAND ...................................................... 4 .......... REPLACES 06020 14901

27 0802081003 TANK, RESERVE 1 28 0602010900 CAP, RESERVE TANK 1 29 C2317100304 BRACKET, RESERVE TANK 1 29 02292 00550 CUSHION, RUBBER 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 81

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

PAGE 82 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

ENGINE & RADIATOR ASSY. (S/N 3708270 AND ABOVE)

NO. PART NO. PART NAME QTY. REMARKS

30 00171 06025 BOLT, HEX HEAD 1 31 00171 08020 BOLT, HEX HEAD 2 32 01999 01900 HOSE 1 33 01936 02000 HOSE 1 34 06055 15170 HOSE BAND 2 35 01936 00560 HOSE 1 36 06055 15170 HOSE BAND 1 37 02691 00650 HOSE 1 38 C23271 00103 PIPE, BREATHER 1 39 00171 08020 BOLT, HEX HEAD 2 40 06033 20112 UBOLT 1 41 02070 08000 NUT, HEX HEAD 2 42 02682 00700 HOSE 1 43 06055 15132 HOSE BAND 2 44 C23583 01003 ROD, CLAMPER 1 45 00171 10020 BOLT, HEX HEAD 2 46 C23583 00003 ROD, CLAMPER 1 47 00171 08020 BOLT, HEX HEAD 1 48 00100 16030 BOLT, HEX HEAD 1 49 00400 16000 WASHER, SPRING 1 50 00412 16000 WASHER, PLAIN 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 83

ENGINE OPERATING PANEL ASSY.

DCA-300SSK ENGINE OPERATING PANEL ASSY.

S/N3701674~

UP TO S/N3701673

PAGE 84 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2352100203 OPERATING PANEL .......................... 1 ......... S/N 3696506 AND BELOW

1 C2352100213 OPERATING PANEL .......................... 1 ......... S/N 3696507 TO 3701673

1 C2352100223 OPERATING PANEL .......................... 1 ......... S/N 3701674 AND ABOVE

2 0017106016 HEX. HEAD BOLT .............................. 8 ......... S/N 3701673 AND BELOW

2 0017106015 HEX. HEAD BOLT .............................. 8 ......... S/N 3701674 AND ABOVE

3 0207006000 HEX. NUT 4 4 0602101000 BATTERY SWITCH 1 5 0021008080 MACHINE SCREW 2 5 0030008000 HEX. NUT 2 5 0040008000 LOCK WASHER 2 5 0041208000 PLAIN WASHER 2

6 0800250300 THROTTLE HANDLE ......................... 1 ......... S/N 3701673 AND BELOW

7 C2484000003 SET FRAME ...................................... 1 ......... S/N 3701674 TO 3708296

7 C2484000303 SET FRAME ...................................... 1 ......... S/N 3708297

8 0017110025 HEX. HEAD BOLT 2

9 8192183004 LINK, GOVERNOR ROD .................... 1 ......... S/N 3701673 AND BELOW

10 0010010035 HEX. HEAD BOLT .............................. 1 ......... S/N 3701673 AND BELOW

11 0030010000 HEX. NUT ........................................... 1 ......... S/N 3701673 AND BELOW

12 0041210000 PLAIN WASHER ................................ 2 ......... S/N 3701673 AND BELOW

13 C2355300404 GOVERNOR ROD .............................. 1 ......... S/N 1337508 TO 3691258

13 C2355300414 GOVERNOR ROD .............................. 1 ......... S/N 3691259 TO 3701673

14 C2355300104 GOVERNOR ROD .............................. 1 ......... S/N 3701673 AND BELOW

15 0602180106 BALL JOINT ....................................... 2 ......... S/N 3701673 AND BELOW

16 0030008000 HEX. NUT ........................................... 2 ......... S/N 3701673 AND BELOW

17 0207006000 HEX. NUT ........................................... 2 ......... S/N 3701673 AND BELOW

18 0041206000 PLAIN WASHER ................................ 2 ......... S/N 3701673 AND BELOW

19 0041206000 PLAIN WASHER ................................ 2 ......... S/N 3701673 AND BELOW

20 505015300 SNAP PIN .......................................... 2 ......... UP TO S/N3701673; REPLACES 0605010502

21 0601830448 PREHEAT BUTTON, AH25FB10 ........ 1 ......... S/N3696507~

22 0601831557 EMERGENCY STOP BUTTON .......... 1 ......... S/N3701674~; AR22V2R01R

23 6008153730 PREHEAT LAMP ................................ 1 ......... REPLACES 0602102055

24 0602120054 TACHOMETER ................................... 1 ......... 25000-KX4110

25 0602120156 CABLE, TACHOMETER ..................... 1 ......... 62500-KA4210L=3000

26 0602122060 OIL PRESSURE GAUGE ................... 1 ......... 42000-KX1410

27 0602122200 UNIT, OIL PRESSURE ....................... 1 ......... 53000-AC0101

28 0602123061 WATER TEMPERATURE GAUGE ...... 1 ......... 40000-KX0910

29 0602123206 UNIT, WATER TEMPERATURE .......... 1 ......... 51400-KS0600

30 0602121052 CHARGING AMMETER ..................... 1 ......... 43000-KV0300

31 0602125060 FUEL GAUGE .................................... 1 ......... 41000-KW0110

32 0602115014 MONITOR ........................................... 1 ......... V337660-0000

33 0601830710 ENGINE SPEED SWITCH, S301T .... 1 ......... S/N3701674~

34 0806410000 STOP BUTTON .................................. 1 ......... UP TO S/N3701673; REPLACES 0602104045

35 6008155390 STARTER SWITCH ............................ 1 ......... UP TO S/N3701673; REPLACES 0602100049

36 615 KEY, STARTER SWITCH ................... 1 ......... UP TO S/N3701673; REPLACES 0602104045

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 85

OUTPUT TERMINAL ASSY.

UP TO S/N3691258

DCA-300SSK OUTPUT TERMINAL ASSY.

S/N3691259~

PAGE 86 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2231700203 SET BOARD, OUTPUT TERMINAL ................ 1 ......... S/N 3708296 AND BELOW

1 8221860203 SET BOARD, OUTPUT TERMINAL ................ 1 ......... S/N 3708297 AND ABOVE

2 0801830404 OUTPUT TERMINAL 8 3 0801830904 HEX. HEAD BOLT 8 4 0039320000 HEX. NUT 16 5 0040020000 LOCK WASHER 24 6 0041420000 PLAIN WASHER 32 7 3501860604 TERMINAL PLATE 3

8 0019108040 HEX. HEAD BOLT ........................................... 5 ......... S/N 3708296 AND BELOW

8 0042308000 LOCK WASHER .............................................. 5 ......... S/N 3708296 AND BELOW

8 0042408000 PLAIN WASHER ............................................. 5 ......... S/N 3708296 AND BELOW

8 0019110050 BOLT, HEX HEAD ........................................... 5 ......... S/N 3708297 AND ABOVE

8 004231000 WASHER SPRING .......................................... 5 ......... S/N 3708297 AND ABOVE

8 004241000 WASHER PLAIN ............................................. 5 ......... S/N 3708297 AND ABOVE

9 0601804887 CIRCUIT BREAKER, KM-51 265V 20A .......... 2 ......... S/N 3691259 TO 3706720

9 0601808803 CIRCUIT BREAKER, QOU120B 20A ............. 2 ......... S/N 3706721~; REPL. 0601805313

10 0601805840 CIRCUIT BREAKER,KM-52 265V 50A ........... 3 ......... S/N 3691259 TO 3706720

10 0601808804 CIRCUIT BREAKER,QOU250B 50A ............... 3 ......... S/N 3706721 AND ABOVE

11 C1261600204 BRACKET, CIRCUIT BREAKER ..................... 1 ......... S/N 3691259 TO 3706720

11 C3261600704 BRACKET, CIRCUIT BREAKER ..................... 1 ......... S/N 3706721AND ABOVE

12 0223300200 RUBBER CUSHION ........................................ 1 ......... S/N 3691259 TO 3706720

12 0221200150 RUBBER CUSHION ........................................ 1 ......... S/N 3706721AND ABOVE

13 0017106020 HEX. HEAD BOLT 2

14 0601812597 RECEPTACLE, 125 V, 20 AMP ....................... 2 ......... S/N 1337508 TO 3691258

14 0601812598 RECEPTACLE, 125 V, 20 AMP ....................... 2 ......... S/N 3691259 AND ABOVE

15 0601811034 RECEPTACLE ................................................. 3 ......... REPLACES 0601812565

16 0027104015 MACHINE SCREW 10 16 0030004000 HEX. NUT 10 16 0041204000 PLAIN WASHER 10

17 C2237100403 COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 1337508 TO 3691258

17 C2237101103 COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 3691259 AND ABOVE

17 C2237101103 COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 3708297 AND ABOVE

18 0019112045 HEX. HEAD BOLT 2 19 0042412000 PLAIN WASHER 2 20 0805009804 RUBBER WASHER 2

20 0805015604 RUBBER WASHER ......................................... 2 ......... S/N 3708297 AND ABOVE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 87

OUTPUT TERMINAL ASSY.

UP TO S/N3691258

DCA-300SSK OUTPUT TERMINAL ASSY.

S/N3691259~

PAGE 88 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

21 020501200 HEX. NUT 2 22 0845043704 SPRING 2

23 C2237100504 COVER ............................................................ 1 ......... S/N 1337508 TO 3691258

23 C2237100514 COVER ............................................................ 1 ......... S/N 3691259 AND ABOVE

23 C2237101204 COVER ............................................................ 1 ......... S/N 3708297 AND ABOVE

24 0017108020 HEX. HEAD BOLT 9

25 C0237101504 COVER, OUTPUT TERMINAL ........................ 1 ......... S/N 3691259 AND ABOVE

26 0805015604 RUBBER WASHER ......................................... 1 ......... S/N 3691259 AND ABOVE

27 0845054204 COLLER .......................................................... 2 ......... S/N 3691259 AND ABOVE

28 0017110040 HEX. HEAD BOLT ........................................... 2 ......... S/N 3691259 AND ABOVE

29 0601815324 TERMINAL BOARD, TS22P ............................ 1 ......... S/N3696507 AND ABOVE

30 0027104020 MACHINE SCREW ......................................... 2 ......... S/N3696507 AND ABOVE

31 0601850275 GROMMET ..................................................... 1 ......... S/N3696507 AND ABOVE

32 0601851780 GROMMET ..................................................... 2 ......... S/N3700674 AND ABOVE

34 C2237101504 COVER ............................................................ 1 ......... S/N 3708297 AND ABOVE

35 C2237400104 BRACKET 1

36 0017106020 BOLT, HEX HEAD ........................................... 2 ......... S/N 3708297 AND ABOVE

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 89

ACTUATOR ASSY. (S/N3701674~)

DCA-300 SSK ACTUATOR ASSY.

PAGE 90 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300 SSK ACTUATOR ASSY.

ACTUATOR ASSY. (S/N 3701674~)

NO. PART NO. PART NAME QTY. REMARKS

1 DYNC110240000024 ACTUATOR ....................................... 1 .............REPLACES 0602150091

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

3 C1356200004 BRACKET, ACTUATOR 1 4 0012310030 HEX. HEAD BOLT 4 5 0010306035 HEX. HEAD BOLT 4 5 0207006000 HEX. NUT 4 5 0040006000 LOCK WASHER 4 5 0041206000 PLAIN WASHER 4 6 0602211091 ROD 1 7 0602180190 BALL JOINT 2 8 0602211092 HEX. NUT 2 9 0010106025 HEX. HEAD BOLT 1 9 0207006000 HEX. NUT 1 9 0041206000 PLAIN WASHER 1 10 0010106025 HEX.HEAD BOLT 1 10 0207006000 HEX. NUT 1 10 0041206000 PLAIN WASHER 4

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 91

BATTERY ASSY.

DCA-300 SSK BATTERY ASSY.

PAGE 92 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300 SSK BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0168614551 BATTERY 2 2 0805000804 BATTERY SHEET 2 3 3972250004 BATTERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 LOCK WASHER 2 7 0041208000 PLAIN WASHER 2 8 C2347600404 BATTERY CABLE 1 9 C2347600104 BATTERY CABLE 1 10 C2347600204 BATTERY CABLE 1 11 C2347600304 BATTERY CABLE 1 12 C2347200004 EARTH CABLE 1 13 0010010030 HEX. HEAD BOLT 4 14 0030010000 HEX. NUT 4 15 0845040414 TERMINAL CAP + 2 16 0845041304 TERMINAL CAP - 2 17 0602220204 BATTERY SENSOR 1

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 93

MUFFLER ASSY.

DCA-300SSK MUFFLER ASSY.

PAGE 94 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2331100002 MUFFLER 1 2 0019210025 HEX. HEAD BOLT 4

3 C2334000003 EXHAUST PIPE .............................................. 1 ......... UP TO S/N 3708296

3 C2234000503 EXHAUST PIPE .............................................. 1 ......... S/N 3708297 AND ABOVE

4 6150115751 GASKET ......................................................... 1 ......... REPLACES 0602320142

5 7502356004 GASKET ......................................................... 1 ......... S/N 1337508 TO 3691258

5 C1334200304 GASKET ......................................................... 1 ......... S/N 3691259 TO S/N 3708296

5 6150115751 GASKET ......................................................... 1 ......... S/N 3708297 ABOVE

6 0010312050 HEX. HEAD BOLT 4 6 0030312000 HEX. NUT 4 6 0040012000 LOCK WASHER 4 6 0041212000 PLAIN WASHER 8 7 0010112055 HEX. HEAD BOLT 4 7 0030012000 HEX. NUT 4 7 0040012000 LOCK WASHER 4 7 0041212000 PLAIN WASHER 8 8 C2331300004 COVER 2 9 0017108020 HEX. HEAD BOLT 4

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 95

FUEL TANK ASSY.

DCA-300SSK FUEL TANK ASSY.

PAGE 96 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C2364000303 FUEL TANK ..................................................... 1 ......... S/N 1337508 TO 2691258

1 C2364000313 FUEL TANK ..................................................... 1 ......... S/N 2691259 AND ABOVE

2 0605505030 CAP, FUEL TANK ............................................ 1 ......... REPLACES 0605505005

2 0601850590 KEY, FUEL TANK ............................................ 1 ......... REPLACES 0601850505

3 0810105400 FUEL FILTER 1 4 0264100485 HOSE, FUEL GAUGE 1

4 0264100525 HOSE, FUEL GAUGE ..................................... 1 ......... S/N 3708297 AND ABOVE

5 0605515079 HOSE BAND 2

6 0605503023 FUEL SENSOR ............................................... 1 ......... FF-9

7 0802120604 PACKING 1

8 0605501050 UNIT FUEL ...................................................... 1 ......... 52000-KA9810

9 0602021155 PACKING ........................................................ 1 ......... 52391-KW3700

10 0027104010 MACHINE SCREW ......................................... 5 ......... S/N 3691259 AND ABOVE

10 0022905015 MACHINE SCREW ......................................... 5 ......... S/N 1337508 TO 2691258

11 8195523104 TANK BAND 2 12 0805003414 PAD, TANK BAND 4 13 0017108020 HEX. HEAD BOLT 2 14 0037908000 HEX. NUT 2 15 0222100300 TANK SHEET 6 16 0130206000 STREET ELBOW 1 17 3515512014 DRAIN PIPE 1

18 0603325011 VALVE ............................................................. 1 ......... BBS-77-15 PT1/2

19 0132006000 PLUG 1 20 0845039604 RUBBER SEAL 1

21 0191302000 SUCTION HOSE ............................................. 1 ......... UP TO S/N 1337973

21 0191302300 SUCTION HOSE ............................................. 1 ......... FROM S/N 1337974

22 0191302240 RETURN HOSE .............................................. 1 ......... UP TO S/N 1337973

22 0191302800 RETURN HOSE .............................................. 1 ......... FROM S/N 1337974

23 0605515109 HOSE BAND 4

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 97

DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)

ENCLOSURE ASSY. (UP TO S/N 3708296)

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER:

THE SERIAL NUMBER MAY BE REQUIRED.

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

PAGE 98 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)

ENCLOSURE ASSY. (UP TO S/N 3708296)

NO. PART NO. PART NAME QTY. REMARKS

1 C2414000002 BASE .............................................................. 1 ......... S/N 1337508 TO 3691258

1 C2414000402 BASE .............................................................. 1 ......... S/N 3691259 TO 3701673

1 C2415000002 BASE .............................................................. 1 ......... S/N 3701674 TO 3708296

2 C3414100104 FLOOR PANEL 1 3 C2414100004 FLOOR PANEL 1 4 0019208020 HEX. HEAD BOLT 14 5 C2414600004 DUCT 1

5 C2494000004 LINING ............................................................ 1 ......... TO S/N 3708296

6 0017108020 HEX. HEAD BOLT 4

7 C2424000402 FRONT FRAME .............................................. 1 ......... S/N3691259 TO 3701673

7 C2425000202 FRONT FRAME .............................................. 1 ......... S/N3701674 TO 3705209

7 C2425000212 FRONT FRAME .............................................. 1 ......... S/N3705210 TO 3708296

7 C2494100003 LINING ............................................................ 1 ......... TO S/N 3708296

8 0019210025 HEX. HEAD BOLT 8 9 C2424200003 COVER, FRONT FRAME 1 10 C2424200104 COVER, FRONT FRAME 1 10 C2494100104 LINING 1 11 0019208020 HEX. HEAD BOLT 26 12 0845042703 FILLER BRACKET 1 13 0019208020 HEX. HEAD BOLT 4 14 C2424200203 COVER, FRONT FRAME 1 15 0019208020 HEX. HEAD BOLT 14

16 C2434000102 CENTER FRAME ............................................ 1 ......... UP TO S/N 1337973

16 C2434000112 CENTER FRAME ............................................ 1 ......... S/N 1337974 TO 3708296

17 0010114050 HEX. HEAD BOLT 4 17 0030014000 HEX. NUT 4 17 0040014000 LOCK WASHER 4 17 0041214000 PLAIN WASHER 8 18 0010114040 HEX. HEAD BOLT 8 18 0030014000 HEX. NUT 8 18 0040014000 LOCK WASHER 8 18 0041214000 PLAIN WASHER 16 19 C2444000302 REAR FRAME 1 19 C2494300204 LINING 1 20 0019210025 HEX. HEAD BOLT 4 21 0017110025 HEX. HEAD BOLT 3 22 C2444300004 COVER, REAR FRAME 1 22 C2494300004 LINING 1

23 C2444300203 DUCT .............................................................. 1 ......... TO S/N 3708296

23 C2494300304 LINING ............................................................ 1 ......... TO S/N 3708296

24 0207008000 HEX. NUT 15 25 C2444300104 PANEL 1 25 C2494300104 LINING 1 26 0017108020 HEX. HEAD BOLT 6 27 0019208020 HEX. HEAD BOLT 14

DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD)— REV. #4 (03/27/06) — PAGE 99

DCA-300SSK ENCLOSURE ASSY. (UP TO S/N 3708296)

ENCLOSURE ASSY. (UP TO S/N 3708296)

THE PART NUMBER ABOVE INDICATES DEFAULT COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER:

THE SERIAL NUMBER MAY BE REQUIRED.

MQGR-GRAY

MQGRN-GREEN

MQW-WHITE

PAGE 100 — DCA-300SSK SERIES — PARTS AND OPERATION MANUAL (STD) — REV. #4 (03/27/06)

Multiquip DCA-300SSK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual