Multiquip Portable Generator DCA 150SSKII User Manual

PARTS AND OPERATION MANUAL

Table of Contents

MQ POWER

MODEL DCA-150SSKII

PORTABLE GENERATOR

Revision #2 (05/08/01)

MULTIQUIPINC.

18910 WILMINGTON AVE.

PARTS DEPARTMENT:

800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

800-421-1244

SERVICE DEPARTMENT:

800-835-2551

FAX:310-537-3927

FAX:310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

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Table of Contents

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HANDWHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 3

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TABLE OF CONTENTS

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

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

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

Rules For Safe Operation .................................... 6-9

Towing ....................................................................10

Trailer Safety Guidlines ..........................................11

Trailer Specifications ........................................ 12-13

Trailer Braking System ..................................... 14-15

Trailer Tires & Suspension ............................... 16-17

Trailer Wire Diagram ..............................................18

Trailer Electric Brakes Troubleshooting ..................19

Trailer Hydraulic Brakes Troubleshooting...............20

Operation And Safety Decals........................... 21-22

Specifications .........................................................23

General Information ...............................................24

Generator Assembly .......................................... 60-61

Control Box Assembly ........................................ 62-65

Engine Radiator Assembly................................. 66-69

Engine Operating Panel Assembly .................... 70-73

Battery Assembly ............................................... 74-75

Muffler Assembly ............................................... 76-77

Fuel Tank Assembly ........................................... 78-79

Enclosure Assembly........................................... 80-83

Enclosure (Rubber Seals).................................. 84-85

Name Plate and Decals ..................................... 86-89

Terms and Conditions Of Sale — Parts ...................90

MQ Power DCA-150SSKII

ACGenerator

Major Components ................................................26

Dimensions (Top, Side And Rear)..........................27

Control Panel.................................................... 28-29

Engine Operating Panel ................................... 30-31

Output Terminal Panel ...................................... 32-39

Installation ........................................................ 40-41

Pre-Setup ......................................................... 42-45

Load Application ....................................................46

Generator Start-Up Procedure (Manual)......... 47-49

Generator Start-Up Procedure (Auto) ...................50

Generator Shut-Down Procedure ..........................51

Maintenance .................................................... 51-53

Troubleshooting (Engine)................................. 54-55

Troubleshooting (Generator/Engine) .....................56

Troubleshooting (MPEC)........................................57

Explanation Of Codes In Remarks Column ...........58

Suggested Spare Parts ..........................................59

NOTE

Specification and part

number are subject to

change without notice.

PAGE 4 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Table of Contents

PARTS ORDERING PROCEDURES

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

Express account number)*

•

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers

and are received by fax qualify for the following extra

discounts:

Number of

line items ordered

Additional Discount

1-9 items

10+ items**

only

der

ed or

For

Get special freight allowances

when you order 10 or more

line items via FAX!**

Now! Direct TOLL-FREE access

to our Parts Department!

■

UPS Ground Service at no charge for freight

■

PS Third Day Service at one-half of actual freight cost

Toll-free nationwide:

800-421-1244

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.

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

800/6-PARTS-7 • 800-672-7877

Fax order discount and UPS special programs revised June 1, 1995

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 5

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Table of Contents

RULES FOR SAFE OPERATION

CAUTION:

Failure to follow instructions in this manual

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engine or generator.

may lead to serious injury or even death!

This equipment is to be operated by trained

and qualified personnel only!This equipment

is for industrial use only.

The following safety guidelines should always be used when

operating the DCA-150SSKII portable generator:

■

High Temperatures – Allow the engine to cool before

adding fuel or performing service and maintenance

functions. Contact with hot components can cause serious

burns.

GENERAL SAFETY

■

DONOToperateorservicethisequipmentbefore

reading this entire manual.

■

This equipment should not be operated by

■

The engine of this generator requires an adequate free

flow of cooling air. Never operate the generator in any

enclosed or narrow area where free flow of the air is

restricted. If the air flow is

persons under 18 years of age.

■

NEVER operatethisequipment without proper

protective clothing, shatterproof glasses,

steel-toed boots and other protective

devices required by the job.

restricted it will cause serious

damage to the generator or

engine and may cause injury

to people. Remember the

generator engine gives off

DEADLY carbon monoxide

gas.

■

NEVER operate this equipment when not

feeling well due to fatigue, illness or taking

medicine.

CAUTION

■

NEVER operate this equipment under the

Always refuel in a well-ventilated area,

away from sparks and open flames.

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.

■

Always use extreme caution when

working with flammable liquids. When

refueling, stop the engine and allow it

to cool. DO NOT smoke around or near

the machine. Fire or explosion could

result from fuel vapors, or if fuel is spilled

on a hot engine.

■

Manufacture does not assume responsibility for any

accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts

■

NEVER operate the generator in an explosive atmosphere

or near combustible materials. An explosion or fire could

result causing severe bodily harm or even death.

before starting.

■

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

fuel.

PAGE 6 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Table of Contents

RULES FOR SAFE OPERATION

CAUTION

DO NOT touch or open any of the below

mentioned components while the

generator is running. Always allow

sufficient time for the engine and generator

to cool before performing maintenance.

■

DO NOT touch output terminals during operation.This is

Radiator

extremely dangerous when your hands are wet. Always

stop the machine when contact with the output terminals

is required.

1. Radiator Cap - Removing the radiator cap while the

engine is hot will result in boiling water to gush out of

the radiator, therefore causing severe scalding to any

persons in the general area of the generator.

CAUTION

■

Backfeed to a utility system can cause electrocution

2. Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant to gush

out of the coolant drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

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.

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

plug while the engine is hot will result in hot oil to gush

out of the oil drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

CAUTION

■

Never use damaged or worn cables when connecting

power tools or equipment to the generator. Make sure the

power connecting cables are securely connected to the

generator’s output terminals. Insufficient tightening of the

terminal connections may cause damage to the generator

and electrical shock.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 7

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RULES FOR SAFE OPERATION

Battery

■NEVER Run engine without an air filter. Severe engine

damage may occur.

CAUTION

■

Always service air cleaner frequently to prevent carburetor

Never over fill the battery with water above

the upper limit.

malfunction.

■Always disconnect the battery before performing service

on the generator.

■

Always be sure the operator is familiar with proper safety

precautions and operations techniques before using

generator.

The battery contains acids that can cause injury to the eyes

and skin.To avoid eye irritation, always wear safety glasses.

Use well insulated gloves when picking up the battery. Use

the following guidelines when handling the battery:

■

Always store equipment properly when not in use.

Equipment should be stored in a clean, dry location out of

the reach of children.

■

DO NOT leave the generator running in the manual mode

unattended.

■

DO NOT allow unauthorized people to operate this

equipment.

■

Always read, understand, and follow procedures in

1. DO NOT drop the battery. There is the possibility the

Operator’s Manual before attempting to operate equipment.

battery may explode.

■

Refer to the Komatsu Engine Owner's Manual for engine

2. DO NOT expose the battery to open flames, sparks,

cigarettes etc. The battery contains combustible gases

and liquids. If these gases and liquids come in contact

with a flame or spark, an explosion could occur.

technical questions or information.

Loading and Unloading (Crane)

■

Before lifting, make sure the generator's lifting hook is

secure and that there is no apparent damage to the

generator itself (loose screws, nuts and bolts). If any

part is loose or damaged, please take corrective action

before lifting.

3. Always keep the battery charged. If the battery is not

charged, a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good

working condition. Repair or replace all worn cables.

■

Always drain fuel prior to lifting.

5. Always recharge the battery in an open air environment,

to avoid risk of a dangerous concentration of combustible

gases.

Always make sure crane or lifting device has been

properly secured to the hook of guard frame on generator.

6. In case the battery liquid (dilute sulfuric acid) comes in

contact with clothing or skin, rinse skin or clothing

immediately with plenty of water.

■

NEVER lift the machine while the engine is running.

Use adequate lifting cable (wire or rope) of sufficient

strength.

7. In case the battery liquid (dilute sulfuric acid) comes in

contact with your eyes, rinse eyes immediately with

plenty of water, then contact the nearest doctor or hospital,

and seek medical attention.

■

When lifting the generator, always use the balanced

center-point suspension hook and lift straight upwards.

NEVER allow any person or animal to stand underneath

the machine while lifting.

When loading the generator on a truck, be sure to use

the front and back frame bars as a means to secure the

generator during transport.

PAGE 8 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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RULES FOR SAFE OPERATION

Transporting

Maintenance Safety

■

Always shutdown engine before transporting.

■

NEVER lubricate components or attempt service on a

running generator.

Tighten fuel tank cap securely.

Drain fuel when transporting generator over long distances

or bad roads.

■

Always allow the engine proper amount of time to cool

before servicing.

■

Always tie-down the generator during transportation by

securing the generator.

■

Keep the generator in proper running condition.

Fix damage to the generator immediately and always

replace broken parts.

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. See page 10 for basic towing procedures.

■

Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant,

fuel, and fuel filters.

Emergencies

■

Always know the location of the nearest fire extinguisher

■

DO NOT use plastic containers to dispose of hazardous

waste.

and first aid kit. Know the location of the nearest telephone.

Also know the phone numbers of the nearest ambulance,

doctor and fire department.

DO NOT pour waste, oil, coolant or fuel directly onto

the ground, down a drain or into any water source.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 9

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Table of Contents

DCA-150SSKII —TOWING

Towing Safety Precautions

■

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

CAUTION :

ALWAYS make sure that the vehicle and trailer

directional, backup, brake, and trailer lights are

connected properly and are working properly.

Check with your county or state safety

towing regulations department before

■

Remember the maximum speed unless otherwise posted

for highway towing is 45 MPH. Recommended off-road

towing is not to exceed 10 MPH or less depending on

type of terrain.

towing your generator.

To reduce the possibility of an accident while transporting

the generator on public roads, always make sure that the

trailer that supports the generator and the towing vehicle

are in good operating condition and both units are

mechanically sound.

■

Place chocked blocks underneath wheel to prevent

rolling, while parked.

Place support blocks underneath the trailer's bumper to

prevent tipping, while parked.

The following list of suggestions should be used when towing

your generator:

Use the trailer's hand winch to adjust the height of the

trailer, then insert locking pin to lock wheel stand in

place, while parked.

■

Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer "gross vehicle

weight rating" (GVWR).

■

Avoid sudden stops and starts.This can cause skidding,

or jackknifing. Smooth, gradual starts and stops will

improve gas milage.

ALWAYS inspect the hitch and coupling for wear. NEVER

tow a trailer with defective hitches, couplings, chains

etc.

■

Avoid sharp turns to prevent rolling.

Remove wheel stand when transporting.

DO NOT transport generator with fuel in tank.

Check the tire air pressure on both the towing vehicle

and the trailer. Also check the tire tread wear on both

vehicles.

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

Figure 1. Generator with Trailer

PAGE 10 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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DCA-150SSKII —TRAILER-SAFETY GUIDELINES

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

CAUTION:

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

ALWAYS make sure the trailer is in good

operating condition. Check the tires for

proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

(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

Explanation of Chart:

axle.

This section is intended to provide the user with trailer ser-

vice and maintenance information. The service and main-

tenance guidelines referenced in this section apply a wide

range of trailers. Remember periodic inspection of the trailer

will ensure safe towing of the equipment and will prevent

damage to the equipment and personal injury.

11. Tire Rim - Tires are mounted on a tire rim. The tire rim

must match the size of the tire.

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

Always use a torque wrench to tighten down the lug

nuts. SeeTable 4 and Figure 5 for lug nut tightening and

sequence.

It is the purpose of this section to cover the major mainte-

nance components of the trailer. The following trailer com-

ponents will be discussed in thie section:

13. Axle - Indicates the maximum weight the axle can sup-

port in pounds, and the diameter of the axle expressed

in inches (see Table 3 on page 17). Please not that

some trailers have a double axle. This will be shown as

2-6000 lbs., meaning two axles with a total weight ca-

pacity of 6000 pounds.

Brakes

Tires

Lug NutTorquing

Suspension

Electrical

14. Suspension - Protects the trailer chassis from shock

transmitted through the wheels. Types of suspension

used are leaf, Q-flex, and air ride.

BrakeTroubleshootingTables

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle. See page 16 for

proper wiring connections.

Use the following definitions while reading Table1.

1. Fuel Cell - Provides an adequate amount of fuel for

the equipment in use. Fuel cells must be empty when

transporting equipment.

16. Application - Indicates which units can be employed

on a particular trailer.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

4. Frame Length - This measurment is from the ball hitch

to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to

fender.

6. Jack Stand - Trailer support device with maximum

pound requirement from the tongue of the trailer.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 11

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DCA-150SSKII —TRAILER-SPECIFICATIONS

Table 1. Specifications

MODEL

APPLICATION

FUEL

CELL

BRAKE

SYSTEM

GVWR

FRAME

LENGTH

FRAME

WIDTH

JACK

STAND

TRLR-10-15

TRLR-10X

TLG-12, DCA15,

TLW-300

1900LBS

2200LBS

2700LBS

2990LBS

7000LBS

10000LBS

11160LBS

14000LBS

18000LBS

30000LBS

96"

85"

50"

42"

800LB.

FULL TILT WHEEL

TLG-12, DCA15,

TLW-300

800LB.

FULL TILT WHEEL

TRLR-10XF

TRLR-225W

BLW-400

TLG-12, DCA15,

TLW-300

51 GAL

800LB.

FULL TILT WHEEL

DCA-10

800LB.

FULL TILT WHEEL

BLW-400

ELECTRIC

W/MAST 154"

W/O 124"

55"

(78" TALL)

800LB.

FULL TILT WHEEL

TRLR-15XF

TRLR-50X

DCA-15

41 GAL

124"

120"

186"

138"

190"

186"

204"

222"

238"

384"

55"

66"

77"

66"

76"

77"

84"

83"

96"

800LB.

FULL TILT WHEEL

DCA-25

800LB.

FULL TILT WHEEL

TRLR-50XF

TRLR-25SBT

TRLR-70W

TRLR-70X

DCA-25

41 GAL

800LB.

FULL TILT WHEEL

DCA-25

800LB.

FULL TILT WHEEL

DCA-45, -60, 70

DCA-100, 125

SURGE

2000LB.

FLAT PAD

OPT

SURGE

2000LB.

FLAT PAD

TRLR-70XF

TRLR-100XF

TRLR-85/125

TRLR-150XF

TRLR-220XF

TRLR-300XF

TRLR-400XF

TRLR-600XF

TRLR-800SX

53 GAL

150 GAL

145 GAL

200 GAL

250 GAL

350 GAL

550 GAL

SURGE

2000LB.

FLAT PAD

HYDRAULIC SURGE

HYDRAULIC

HYDRAULIC SURGE

ELECTRIC

AIR

2000LB.

FLAT PAD

DCA-85, 100,

125

2000LB.

FLAT PAD

DCA-150, 180

5000 LB.

FLAT PAD

DCA-220

5000 LB.

FLAT PAD

DCA-300

5000 LB.

FLAT PAD

DCA-400

5000 LB.

FLAT PAD

DCA-600, 800

5000 LB.

FLAT PAD

AIR

5000 LB.

FLAT PAD

PAGE 12 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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DCA-150SSKII —TRAILER-SPECIFICATIONS

Table 1. Specifications (Con't)

MODEL

COUPLER

TIRES

WHEELS

AXLE

HUBS SUSPENSION

ELECTRICAL

TRLR-10-15W

2" BALL CLASS

2 ADJUSTABLE

175-13C

13"X4.50"

2200# 2X2

5 LUG

6 LUG

8 LUG

3 LEAF

Q FLEX

3 LEAF

4 LEAF

5 LEAF

7 LEAF

Q FLEX

7 LEAF

AIR-RIDE

4 WIRE LOOM W/

4 POLE FLAT

TRLR-10X

TRLR-10XF

TRLR-225W

BLW 400

2"BALL CLASS

2 ADJUSTABLE

175-13C

13"X4.5"

13X4.5"

13 X 4.5"

13"X4.50"

14"X5"

2200#2X2

3500# 2-1/2"

4 POLE FLAT

2"BALL CLASS

2 ADJUSTABLE

2"BALL CLASS

2 ADJUSTABLE

175-13B

2"BALL CLASS

2 ADJUSTABLE

175-13C

TRLR-15XF

TRLR-50X

TRLR-50XF

TRLR-70W

TRLR-70X

TRLR-70XF

2" BALL CLASS

B78-13LRC

4 POLE RUBBER

FLAT

3500lbs.

2-3/8"

4 POLE RUBBER

FLAT

3500lbs.

2-3/8"

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

3500lbs.

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

14"X5"

3500lbs

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

14"X5"

3500lbs.

4 POLE RUBBER

FLAT

TRLR-100XF ADJUSTABLE 2-5/6

205-15C

BIAS (4)

14"X5.5"

14"x6"

3500lbs

4 WIRE LOOM

6 WIRE LOOM

OPT 3" EYE

TRLR-85/125 ADJUSTABLE 2-5/6

ST225/75R15D

RADIAL (4)

(2)-6000lbs

(2)-7000lbs

(2)-6000lbs

(3)-7000lbs.

(3)-10000lbs

OPT 3" EYE

TRLR-150XF

TRLR-220XF

TRLR-300XF

TRLR-400XF

TRLR-600XF

TRLR-800AR

3" BALL EYE

750-16 E

BIAS (4)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(4)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(6)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(6)

16"X7"

5TH WHEEL

ST215/75R17.5H

RADIAL (8)

16"X7"

5TH WHEEL

ST215/75R17.5H

RADIAL (8)

16"X7"

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 13

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DCA-150SSKII —TRAILER BRAKING SYSTEM

Brakes

synchronization between the tow vehicle and the trailer

If your trailer has a braking system, the brakes should be

inspected the first 200 miles of operation. This will allow

the brake shoes and drums to seat properly. After the first

200 mile interval, inspect the brakes every 3,000 miles. If

driving over rough terrain, inspect the brakes more

frequently.

being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be

made, the trailer brakes should be burnished-in by applying

the brakes 20-30 times with approximately a 20 m.p.h.

decrease in speed, e.g. 40 m.p.h. to 20 m.p.h.. Allow ample

time for brakes to cool between application. This allows

the brake shoes to slightly be seated into the brake drum

surface.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to

hydraulic brakes. The basic difference is that hydraulic

brakes are actuated by an electromagnet.

Figure 2 displays the major electric brake components that

will require inspection and maintenance. Please inspect

these components as required. Refer toTable 5 for electric

brake troubleshooting guidelines.

Listed below are some of the advantages that electric

brakes have over hydraulic brakes:

An electric brake system can be manually adjusted to

provide the corrected braking capability for varying road

and load conditions.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

An electric brake system can be modulated to provide

more or less braking force, thus easing the brake load

on the towing vehicle.

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.

An electric brake system has very little lag time between

the time the vehicle’s brakes are actuated and the

trailer’s brakes are actuated.

4. With a screwdriver or standard adjusting tool, rotate

the star wheel of the adjuster assembly to expand the

brake shoes.

An electric brake system can provide an independent

emergency brake system.

5. Adjust the brake shoes outward until the pressure of

the lining against the wheel drum makes the wheel

difficult to turn.

Road testing is necessarry in order to properly synchronize

the towing vehicle’s braking to the trailer’s braking. Brake

lockup, grabbiness, or harshness is due to lack of

6. Rotate the star wheel in the opposite direction until the

wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer

to the ground.

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

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DCA-150SSKII —TRAILER BRAKING SYSTEM

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Figure 3 below displays the major hydraulic/air/surge brake

Hydraulic brakes (Figure 3) should not require any special

attention with the exception of routine maintenance such

as shoe and lining replacement. These brakes can be

adjusted in the same manner as electric brakes. Brake

lines should be periodically checked for cracks, kinks, or

blockage.

components that will requrie inspection and maintenance.

Inspect these components as required using steps 1

through 6 as referenced in the electric brake adjustments

section. Refer toTable 6 for hydraulic brake troubleshooting

guidelines.

Figure 3. Hydraulic Brake Components

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DCA-150SSKII —TRAILERTIRES & SUSPENSION

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing

the trailer wheels it is important the wheels, tires, and axle

are properly matched.

CAUTION:

DO NOT attempt to repair or modify a

wheel. DO NOT install an inner tube to

correct a leak through the rim. If the

rim is cracked, the air pressure in the

inner tube may cause pieces of the rim

to explode (break off) with great force and cause serious

eye or bodily injury.

Suspension

The leaf suspension springs and associated components

(Figure 4) should be visually inspected every 6,000 miles

for signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 3.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in

preserving tire life. Pressure should be checked cold before

operation. DO NOT bleed air from tires when they are hot.

Check inflation pressure weekly to insure the maximum

tire life and to prevent premature tread wear.

Table 2 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing

or installing force fitted parts. Failure to

comply may result in serious injury.

Figure 4. Suspension Components

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DCA-150SSKII —TRAILERTIRES & SUSPENSION

Table 3. Suspension Torque Requirements

Item

Torque (Ft.-Lbs.)

3/8" U-BOLT

7/16" U-BOLT

1/2" U-BOLT

MIN-30 MAX-35

MIN-45 MAX-60

SHACKLE BOLT

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN NUT-BOLT ASSEMBLY

PARTS MUST ROTATE FREELY.

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

MIN-30 MAX-50

Lug NutTorque Requirements

It is extremely important to apply and maintain proper wheel

mounting torque on the trailer. Be sure to use only the

fasteners matched to the cone angle of the wheel. Proper

procedure for attachement of the wheels is as follows:

1. Start all wheel lug nuts by hand.

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

NOT torque the wheel lug nuts all the way down. Tighten

each lug nut in 3 separate passes as defined by Table

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

Check all wheel lug nuts periodically for continued safe

operaion.

Table 4. Tire Torque Requirements

Wheel Size

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

12"

13"

14"

15"

16"

20-25

35-40

50-60

50-65

90-120

Figure 5. Lug Nut Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 17

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DCA-150SSKII — TRAILERWIRING DIAGRAMS

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

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DCA-150SSKII — TRAILER-BRAKETROUBLESHOOTING

Table 5. Electric Brake Troubleshooting

Symptom

Possible Cause

Any open circuits or broken wires?

Any short circuits?

Solution

No Brakes or Intermittent Brakes

Find and correct.

Test and correct.

Find and repair.

Find and secure.

Clean or replace.

Faulty controller?

Any loose connections?

Ground wire secure?

Weak Brakes or Brakes Pull to

One Side

Grease or oil on magnets or linings?

Connections corroded?

Clean and correct cause

of corrosion.

Brake drums scored or grooved?

Brakes synchronized?

Machine or replace.

Correct.

Locking Brakes

Noisy Brakes

Brake components loose, bent or broken?

Brake drums out-of-round?

Replace components.

Replace.

Systemlubricated?

Lubricate.

Brake components correct?

Bearings of the wheel adjusted?

Replace and correct.

Adjust.

Dragging Brakes

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DCA-150SSKII —TRAILER-BRAKETROUBLESHOOTING

Table 6. Hydraulic Brake Troubleshooting

Symptom

Possible Cause

Brake line broken or kinked?

Brake lining glazed?

Solution

Repair or replace.

Reburnish or replace.

Correct weight.

No Brakes

Weak Brakes or Brakes Pull to

One Side

Trailer overloaded?

Brake drums scored or grooved?

Tire pressure correct?

Machine or replace.

Inflate all tires equally.

Match tires.

Tires unmatched on the same axle?

Brake components loose, bent or broken?

Brake drums out-of-round?

Systemlubricated?

Locking Brakes

Noisy Brakes

Replace components.

Replace.

Lubricate.

Brake components correct?

Replace and correct.

Dragging Brakes

Brake lining thickness correct or in right

wrong position?

Install new shoes and

linings.

Enough brake fluid or correct fluid?

Replace rubber parts

fill with dot4 fluid.

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DCA-150SSKII — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-150SSKII generator is equipped with a number of safety decals.These decals are provided for operator

safety and maintenance information.The illustration below and on the preceding page shows these decals as they

appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your

dealer.

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DCA-150SSKII — OPERATION AND SAFETY DECALS

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DCA-150SSKII — SPECIFICATIONS

Table 7. Specifications

Generator Specifications

Model

Type

DCA-150SSKII

Revolving field, self ventilated, open protected type

synchronous generator

Star with Neutral

Zig Zag

Single

96KW

87KW

240V

Armature Connection

Phase

Standby Output

Prime Output

Voltage

165 KVA (132 KW)

150 KVA (120 KW)

240V or 480V

Frequency

Speed

60 Hz

1800 rpm

Power Factor

Aux. AC Power

Voltage

0.8

Single Phase, 60 Hz

120 V

Output

4.8 KW (2.4 KW x 2)

Engine Specifications

Model

Type

KOMATSU S6D108E-2

4-cycle, water-cooled, direct injection, turbo-charged

6 cylinders

No. of Cylinders

Bore x Stroke

Rated Output

Displacement

Starting

4.25 in. x 5.11 in. (108 mm x 130 mm)

180HP/1800 rpm

436 cu. in. (7150 cc)

Electric

Coolant Capacity

Lube Oil Capacity

7.4 gal. (28 liters)

6.6 gal. (25 liters)

9.2 gal. (34.8L)/hr at full

6.9 gal. (26.1L)/hr at 3/4 load

load

Fuel Consumption

4.8 gal. (18.2L)/hr at 1/2

3.2 gal. (12.1L)/hr at 1/4 load

load

Battery

Fuel

12V- 120AHx2

#2 Diesel Fuel

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 23

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DCA-150SSKII — GENERAL INFORMATION

DCA-150SSKII FAMILIARIZATION

Generator

Microprocessor Controlled Alarm System

The DCA-150SSKII generator is equipped with various

alarms and LED status indicators.These alarms and status

indicators are provided to add safety to the generator when

operating under normal conditions. The DCA-150SSKII

generator is designed to shutdown in the event of low oil,

high coolant temperature, low battery and other operation

conditions that may cause severe damage to the generator.

The MQ Power Model DCA-150SSKII is a 120 kW generator

that is designed as a high quality portable (requires a trailer

for transport) power source for telecom sites, lighting

facilities, power tools, submersible pumps and other

industrial and construction machinery.

Engine Control Panel

The “Engine Control Panel” is provided with the following:

Open Delta Excitation System

Tachometer

The DCA-150SSKII generator is equipped with the state of

the art "Open-Delta" excitation system. The open delta

system consist of an electrically independent winding wound

among stationary windings of the AC output section.

WaterTemperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

EngineWarning Lamp Module

Engine Throttle Lever

Pre-Heat Button

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

power to the AutomaticVoltage Regulator (AVR) is supplied

from the leads parallel connections of B&C. When loads

increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with

load. This of adding the voltages to each phase provides

better voltage response during heavy loads.

Pre-Heat Lamp

Generator Control Panel

The “Generator Control Panel”is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Panel Light

The connections of the AVR to the AC output windings are

for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation

current, offering maximum motor starting capabilities. The

excitation does not have a "fixed ceiling" and responds

according the demands of the required load.

Panel Light Switch

MPEC Module

Engine

The DCA-150SSKII is powered by a 4-cycle water cooled,

turbocharged KOMATSU Model S6D108E-2 diesel engine.

This engine is designed to meet every performance

requirement for the generator. Reference Table 1, page 13

for engine specifications.

Output Terminal Panel

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

Three 240/139V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 265V @65 amps

2 Load GFCI Circuit Breakers 265V@ 20amps

In keeping with MQ Power's policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

The basic controls and indicators for the DCA-150SSKII

generator are addressed on the following pages.

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 400 amps

Over-Current Relay

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DCA-150SSKII — MAJOR COMPONENTS

Figure 6. Major Components

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DCA-150SSKII — DIMENSIONS (TOP, SIDE, AND REAR)

Figure 7. Dimensions

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DCA-150SSKII — CONTROL PANEL

Figure 8. Control Panel

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DCA-150SSKII — CONTROL PANEL

The definitions below describe the controls and functions of During cranking cycle , The MPEC will attempt to crank

the DCA-150SSKII " Control Panel "(Figure 8).

the engine for 10 seconds before disengaging.

If the

engine does not engage (start) by the third attempt, the

engine will be shut-down by the MPEC's " Over Crank

Protection" mode. If the engine engages at a speed (RPM's)

that is not safe, the MPEC will shut-down the engine by

initializing the "Over Speed Protection" mode.

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz ±1 Hz .

2. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

3. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the

load connected to any phase of the output terminals, or

to be switched off.

Also the MPEC will shut-down the generator in the event

of low oil pressure, high coolant temperature, low coolant

level, and loss of magnetic pickup. These conditions can

be observed by monitoring the LED status indicators on

the front of the MPEC module.

4. AC Voltmeter – Indicates the single phase output

voltage present at the UNV terminals.

5. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage

between any two phases of the output terminals or to

be switched off.

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

running of the generator.If this switch is left in the "OFF"

position, the generator will not run. When this switch is

set to the manual position, the generator will start

immediately.

6. Pilot Lamp – Indicates that the generator is working

properly.

If the generator is to be connected to a building's AC

power source via a transfer switch (isolation), place

the switch in the auto position. In this position the

generator will monitor the AC line output from the

building's power source.

7. Main Circuit Breaker – This three-pole, 600 amp main

breaker is provided to protect the UNV voltage output

terminals from overload.

8. Voltage Regulator Control – Allows manual

adjustment of the generator’s output voltage

B. Low Oil Pressure – Indicates the engine pressure

has fallen below 15 psi. The oil pressure is detected

using variable resistive values from the oil pressure

sending unit. This is considered a major fault.

9. Panel Light – Normally used in dark areas or at night

time.When activated, panel lights will illuminate.When

the generator is not in use be sure to turn the panel

light switch to the OFF position.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 215°F. The engine

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

temperature is detected using variable resistive values

from the temperature sending unit. This is considered

a major fault.

panel light.

11. MPEC – Microprocessor Engine Control Module –

(MPEC) has a vertical row of status LED's (Figure 9),

that when lit, indicate that a engine malfunction (fault),

has been detected. When a

D. Overcrank Shutdown – Indicates the unit has

attempted to be started a pre- programmed number of

times, and has failed to start. The number of cycles

and duration are programmable. It is pre-set at 3 cycles

with a 10 second duration. This is considered a major

fault.

fault has been detected the

MPEC will evaluate the fault

and all major faults will

shutdown the generator.

E. Overspeed Shutdown – Indicates that the engine is

running at an unsafe speed.This is considered a major

fault.

Engine Running – Indicates that engine is running

at a safe operating speed.

Figure 9. MPEC Module

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DCA-150SSKII — ENGINE OPERATING PANEL

Figure 10. Engine Operating Panel

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DCA150SSKII — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of D. Low Battery Fluid Lamp – This lamp goes

the DCA-150SSKII " Engine Operating Panel "(Figure 10).

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.

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

Hz operation. This meter should indicate 1800 RPM’s

when the rated load is applied. In addition a built in hour

meter will record the number of operational hours that

the generator has been in use.

2. WaterTemperature Gauge – During normal operation E. Clogged Air Filter Lamp – This lamp goes

this gauge be should read in the “GREEN” zone.

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.

3. Oil Pressure Gauge – During normal operation this

gauge be should read in the “GREEN” zone. When

starting the generator the oil pressure mar read a little

bit higher, but after the engine warms up the oil pressure

should return to the green zone.

7. Pre-Heat Lamp – Indicates that the glow

plugs of the diesel engine are hot and the

engine is ready to be started.

4. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides

current for generator’s control circuits and battery

charging system.

8. Pre-Heat Button – Press hold this button

until the pre-heat lamp is lit (ON).

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

6. Engine Warning Display Module – This module

display’s the following engine failures:

9. Throttle Handle - This handle controls the

speed of the engine (low or high).

A. Overheat Lamp – This lamp goes ON when

the cooling water temperature rises

abnormally. If the lamp goes ON during

normal operation of the generator, the

emergency shut-down device will stop the

engine automatically.

B. Low Oil Pressure Lamp – During normal

operation of the generator this lamp should

remain OFF. When the Auto-OFF/Reset-

Manual switch is set to the “Manual” position

to start the engine, the lamp will be lit.After

the oil pressure rises after start-up the lamp

will go OFF. If this lamp is ever lit (ON) during normal

operation of the generator, the emergency shut-down

device will stop the engine automatically.

C. Low Fuel Level Lamp – When this lamp

is ON, it is time to stop the engine and add

fuel. Remember to let the engine cool

before adding fuel.

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

Connecting Load

OUTPUTTERMINAL PANEL FAMILIARIZATION

Loads can be connected to the generator by the UNV Lugs or

the convienience receptacles. (See figure 13). Make sure to

read the operation manual before attempting to connect a load

to the generator.

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

Three 240/139V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 265V @65 amps

2 Load GFCI Circuit Breakers 265V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 400 amps

Over-Current Relay

Output Terminal Panel

The Output Control Panel (See Figure 14) is located on the

right hand side (left from control panel) of the generator.

The UNV lugs are protected by a face plate cover that can

be secured in the close position by a pad lock. (See Figure

11).

FIGURE 13. Connecting Load

Circuit Breakers

To protect the generator from an overload, a 3-pole, 400 amp,

main circuit breaker is provided to protect the UNV output

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

GFCI circuit breakers are provided to protect the GFCI

receptacles from overload.Three 50 amp load circuit breakers

have also been provided to protect the load side of the

generator from overload. Make sure to switch ALL circuit

breakers to the "OFF" position prior to starting the engine.

Maximum Output

The entire load connected to the UNV Lugs, all four slots in the

duplex receptacles, and the must not exceed 132 kW in

standby or 120 kW in prime output.

FIGURE 11. Output Terminal Cover

120Volt Recetacle

Two GFCI Duplex Nema 5-20R (120V, 20 Amp) recepacle is

provided on the output terminal. This receptacle can be

used anytime the generator is in operation. The receptacle

is controlled by the circuit breaker located on the control

panel.

Twist Lock DualVoltage Receptacles - To use these

receptacles, place the voltage selector switch in the single

phase 240/120 voltage position and adjust the output

voltage to 240 volts with the voltage regulator on the

Control Panel (see figure 14). Place the voltmeter change-

over switch to the U-W positon and the ammeter change-

over switch to the U or W to read the output.

Pressing the reset button resets the receptacle after being

tripped. Pressing the "Test Button" (See Figure 12) in the

center of this receptacle will check the GFCI function. The

receptacle should be tested at least once a month.

FIGURE 12. GFCI Test Button

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

NOTE

Legs

and Ground are

considered Bonded Grounds.

FIGURE 14. Output Terminal Panel

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

Maximum Amps

Output Terminal Panel Available Voltages

The following table show the maximum amps the entire

generator can provide. Do not exceed the maximum amps

listed. (See Table 9)

A wide range of voltages are available to supply load to

many different applications. Voltages may be selected by

using the voltage selector switch and how you hookup

your hard wire connection to the generator. To obtain some

of the voltages listed, fine adjustment with the Voltage

Regulator on the control panel is necessarry. See the

table below (Table 8) for a list of available voltages the

generator is able to supply.

Table 9. Maximum Amps

Model:

DCA150SSKll

Maximum Amps

333.3 amps (4 wire)

166.7 amps (4 wire)

361 amps

TABLE 8. VOLTAGES AVAILABLE

Rated

Voltage

MODEL

DCA150SSKll

3 PHASE VOLTAGE

(SWITCHABLE)

208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT

120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT

Single Phase

120 Volt

SINGLE PHASE

(SWITCHABLE)

Single Phase

240 Volt

Voltage Selector Switch

The voltage selector switch is located above the UVWO

Hard Wire Hook-up Panel. It has been provided for ease of

voltage selection.

Three Phase

240 Volt

Three Phase

480 Volt

CAUTION :

180 amps

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Receptacle Use

When the UVWO terminals are providing power, the

receptacle power available decrease. Do not exceed

receptacle power available listed on Table 10.

Voltage Selector Switch Locking Button

Table 10. Receptacle Use

Receptacle

The voltage selector switch has a locking button to protect

the generator and generator load from being switched while

the engine is running. To lock the Voltage Selector Switch,

press in the red button located on the Voltage Selector

Switch, and use a pad lock to hold it into this position.

Power in Use

Power

Available

240/120V

240/480V Single Phase

Over Current Relay

Duplex

NEMA

5-20R 120V

An over current relay is connected to the circuit breaker.

In an over current situation, both the circuit breaker and

the over current relay may trip. If the circuit breaker can

not be reset, the reset button on the over current relay

must be pressed. The over current relay is located in the

control box.

3-Phase

or Twist

Lock CS6369

KVA

150

146

142

138

133

85.8

84.6

83.4

82.2

1.2

2.4

3.6

4.8

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

How to read the output terminal guages.

The guages and knobs on the control panel DO NOT effect

the generator output in any fashion. They are there to

simply help the operator observe how much power is being

supplied produced at the UVWO legs.

When the voltage selector switch is in the 240/120V

position (see figure 15), place the AC Voltmeter Change-

over switch to the W-U position and the AC ammeter

Change-over Switch to the U or W position to read the

output on the selected leg.

FIGURE 19. ACAmmeter

(Amp reading on U lug)

FIGURE 18. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

NOTE

When using plural single phase

voltages, make sure to balance

the load on each of the single

phase legs.

FIGURE 15. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 16. AC Voltmeter

FIGURE 17. AC Voltmeter

Change-over switch

Guage

(Reading the W-U leg on

(Volt reading on W-U Lug)

the outputerminal panel)

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

240/120V HardWire Hookup

480/240V Hard Wire Hookup

The output terminal panel, when suppling single phase 120

volts, will provide three legs available with 333.3 amps each

on three different circuits. (See Figure 21 below.) The voltage

selector switch must be set at the single phase 240/120V

position. (See figure 20 below.)

The output terminal panel, when suppling three phase 240

volts, will provide one circuit available at 361 amps with any

two wires plus the ground.(See Figure 23 below.) The voltage

selector switch must be set at the three phase 480/277V

position. (See figure 22 below.)

The output terminal panel, when suppling single phase 240

volts, will provide one leg only with 166.7 amps available.

(See Figure 21 below.) The voltage selector switch must be

set at the single phase 240/120V position. (See figure 20

below.)

The output terminal panel, when suppling 3 phase 480 volts,

will provide one circuit available at 180 amps available with

all three wires plus ground. (See Figure 23 below.) The

voltage selector switch must be set at the three phase 480/

277V position. (See figure 22 below.)

FIGURE 22. Voltage Selector Switch 480/277V Three Phase

Position

FIGURE 20. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 23. Hard Wire Hook-up at 480/240V Position

FIGURE 21. Hard Wire Hook-up at 240/120V Position

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

Voltage Selector Switch- 3 Phase 480/277V Position

Single Phase: 480V, 440V, or 416 Volt

The following are additional voltages available when the

voltage selector switch is in the 3 phase 480/277V

position. (See figure 24 below.)

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 24),

can offer SINGLE PHASE power at 480V, 440V, or 416V.

After hooking up the hard wires to the lugs as shown in

figure 27 below, 480V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 440 volt will be

reached when the Voltage Regulator Knob is turned down,

and 416 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 25).

FIGURE 25. Voltage

Regulator Knob Located

on the Control Panel.

FIGURE 24. Voltage Selector Switch 480/277V Single Phase

Position

FIGURE 27. Hard Wire Hook-up for Single Phase 480V, 440V,

or 416V

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

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

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 24),

can offer SINGLE PHASE power at 277V, 254V, or 240V.

After hooking up the hard wires to the lugs as shown in

figure 28 below, 277V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 254 volt will be

reached when the Voltage Regulator Knob is turned down,

and 240 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 25).

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 24),

can offer THREE PHASE power at 480V, 440V, or 416V.

After hooking up the hard wires to the lugs as shown in

figure 26 below, 480V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 440 volt will be

reached when the Voltage Regulator Knob is turned down,

and 416 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 25).

FIGURE 26. Hard Wire Hook-up for Three Phase 480V, 440V,

or 416V

FIGURE 28. Hard Wire Hook-up for Single Phase 277V, 254V,

or 240V

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

Voltage Selector Switch- 3 Phase 240/139V Position

Single Phase: 240V, 220V, or 208 Volt

The following are additional voltages available when the

voltage selector switch is in the 3 phase 240/139V

position. (See Figure 29 below.)

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 29),

can offer SINGLE PHASE power at 240V, 220V, or 208V.

After hooking up the hard wires to the lugs as shown in

figure 32 below, 240V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 220 volt will be

reached when the Voltage Regulator Knob is turned down,

and 208 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 30).

FIGURE 30. Voltage

Regulator Knob located

on the control panel

FIGURE 32. Hard Wire Hook-up for Single Phase 240V, 220V,

or 208V

FIGURE 29. Voltage Selector Switch 240/139V Three Phase

Position

Single Phase: 139V, 127V, or 120V

3 Phase, 240V, 220V, or 208 Volt

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 29),

can offer SINGLE PHASE power at 139V, 127V, or 120V.

After hooking up the hard wires to the lugs as shown in

figure 33 below, 139V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 127 volt will be

reached when the Voltage Regulator Knob is turned down,

and 120 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 30).

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 29),

can offer THREE PHASE power at 240V, 220V, or 208V.

After hooking up the hard wires to the lugs as shown in

figure 31 below, 240V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 220 volt will be

reached when the Voltage Regulator Knob is turned down,

and 208 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 30).

FIGURE 33. Hard Wire Hook-up for Single Phase 139V, 127V,

or 120V

FIGURE 31. Hard Wire Hook-up for Three Phase 240V, 220V,

or 208V

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DCA-150SSKII — OUTPUTTERMINAL PANEL OVERVIEW

Voltage Selector Switch- Single Phase 240/120V

Position

The following are additional voltages available when the

voltage selector switch is in the single phase 240/120V

position. (See Figure 34 below.)

Single Phase: 120 Volt

The following connection, with the voltage selector switch

locked into the single phase 240/120V position (See

Figure 34), will offer SINGLE PHASE power at 120V. After

hooking up the hard wires to the lugs as shown in figure 37

below, use the Voltage Regulator Knob to fine tune to

120V. (See Figure 35).

FIGURE 35. Voltage

Regulator Knob located

on the control panel

FIGURE 34. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 37. Hard Wire Hook-up for Single Phase, 120 volt

Single Phase, 240 Volt

The following connection, with the voltage selector switch

locked into the single phase 240/120V position (See

Figure 34), will offer SINGLE PHASE power at 240V. After

hooking up the hard wires to the lugs as shown in figure 36

below, use the Voltage Regulator Knob to fine tune to

240V. (See Figure 35).

FIGURE 36. Hard Wire Hook-up for Single Phase 240 volt

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DCA-150SSKII — INSTALLATION

CAUTION

Outdoor Installation

Install the generator in a location where it will not be exposed

to rain or sunshine. Make sure that the generator is on secure

level ground so it cannot slide or shift around. Also install

the generator so the exhaust will not be discharged in the

direction of nearby homes.

An electric shock is apt to happen when

vibrators are used. Pay close attention to

handling when operating vibrators and

always use rubber boots and gloves to

insulate the body from electrical shock.

Generator Grounding

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

of the insulation and will result in short circuits and grounding.

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.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear, not

only to the engine parts, but also to the alternator parts.

CAUTION :

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

grounding requirements:

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.

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.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

must be vented to the outside.The engine should be installed

at least two feet from any outside wall. Using an exhaust

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat

excessively and possibly burn the valves.

2. When grounding the generator (Figure 9) connect the

ground cable between the lock washer and the nut on

the generator and tighten the nut fully.Connect the other

end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried a minimum of 8 ft. into the ground.

DO NOT cover ventilation areas on the enclosure, covering

the ventilation grids will cause the engine to over heat.

NOTE

When connecting the generator to any buildings

electrical system ALWAYS consult with a licensed

electrician.

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DCA-150SSKII — INSTALLATION

Figure 38. Typical Generator Grounding Application

CAUTION

Always check Local, State, and Federal

laws before grounding generator set.

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DCA-150SSKII — PRE-SETUP

General Inspection Prior to Operation

Circuit Breakers

The DCA-150SSKII generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 400 amp,

and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UNV output

be sure to check for damaged parts or components, or loose terminals from overload. In addition two single-pole, 20 amp

nuts and bolts, which could have occurred in transit.

GFCI circuit breakers are provided to protect the GFCI

receptacles from overload.Three 50 amp load circuit breakers

have also been provided to protect the load side of the

generator from overload. Make sure to switch ALL circuit

breakers to the "OFF" position prior to starting the engine.

Extension Cable

When electric power is to be provided to various tools or

loads at some distance from the generator, extension

cords are normally used. Cables should be sized to allow

for distance in length and amperage so that the voltage

drop between the generator and point of use (load) is held

to a minimum. Use Table 11 (cable selection guide) as a

guide for selecting proper cable size.

NOTE

ALWAYS consult with a licensed

electrician for correct extension

cord wire size.

Table 11. Cable Selection (60 Hz, Single Phase Operation)

Load In Watts

Maximum Allowable Cable Length

Current

Amperes

At 120

240

#10 Wire

#12 Wire

#14 Wire

#16 Wire

Volts

2.5

300

600

1000 ft.

500 ft.

350 ft.

250 ft.

150 ft.

125 ft.

600 ft.

300 ft.

200 ft.

150 ft.

100 ft.

75 ft.

375 ft.

200 ft.

125 ft.

100 ft.

65 ft.

250 ft.

125 ft.

100 ft.

1200

1800

2400

3600

4800

7.5

900

1200

1800

2400

50 ft.

CAUTION: Equipment damage can result from low voltage.

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DCA-150SSKII — PRE-SETUP

Fuel

Lubrication Oil

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

fill the tank beyond capacity.

Fill the engine crankcase with lubricating oil through the filler

hole, but do not overfill. Make sure the generator is level.

With the dipstick inserted all the way, but without being screw

into the filler hole, verify that the oil level is maintained

between the two notches (Figure 39) on the dipstick. See

Table 3 for proper selection of engine oil.

Pay attention to the fuel tank capacity when replenishing

fuel. Refer to the fuel tank capacity listed on page 23,

Specification Table 7.

The fuel tank cap must be closed tightly after filling. Handle

fuel in a safety container. If the container does not have a

spout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION _{Never fill the fuel tank while the engine is}

running or in the dark. Diesel spillage on a

hot engine can cause a fire or explosion.

If diesel spillage occurs, wipe up the

spilled diesel completely to prevent fire

hazards.

Coolant

Use only drinkable tap water. If hard water or water with

many impurities is used, the inside of the engine and radiator

may become coated with deposits and cooling efficiency

will be reduced.

Figure 39. Engine Oil Dipstick

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system. See the engine

manual for further details.

When checking the engine oil, be sure to check if the oil is

clean and viscous. If the oil is not clean, drain the oil by

removing the oil drain plug, and refill with the specified amount

of oil as outlined in the Komatsu Engine Owner's Manual.

Table 12. Recommended Motor Oil

Temperature

Range

Type Oil

104° F ~ 23° F

(40° C ~ -5°C)

SAE 30

23° F ~ 5° F

(-5° C ~ -15°C)

SAE 20 or SAE 10W-30

SAE 10W or SAE 10W-30

Below 5° C (-15°)

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DCA-150SSKII — PRE-SETUP

Cleaning the Radiator

CAUTION :

The radiator may overheat if the fins become overloaded

with dust or debris. Periodically clean the radiator fins with

compressed air. Cleaning inside the machine is dangerous,

so clean only with the engine turned off and the battery

disconnected.

When adding coolant or antifreeze to the

radiator, do not remove the radiator cap

until the unit has completely cooled.

Air Cleaner

Day-to-day addition of coolant is done from the reserve tank.

When adding coolant to the radiator, DO NOT remove the

radiator cap until the unit has completely cooled. See Table

13.for engine, radiator, and reserve tank coolant capacities.

Make sure that the coolant level in the reserve tank is always

between the "H" and the "L" markings.

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.

Table 13. Coolant Capacity

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

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

below.

Engine and Radiator

Reserve Tank

7.4 Gal. (28 Liters)

2 Quarts (11.9 Liters)

Operation in Freezing Weather

When operating in freezing weather, be certain that the proper

amount of antifreeze (Table 14) has been added.

Figure 40. Fan Belt Tension

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

Table 14. Anti-Freeze Operating Temperatures

CAUTION

Freezing Point

Boiling Point

Never place hands near the belts or fan

while the generator set is running.

Vol %

Anti-Fre-

eze

°C

-24

-37

°F

°C

°F

Battery

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

Always maintain battery fluid level between the specified

marks. Battery life will be shortened, if the fluid level is not

properly maintained. Add only distilled water when

replenishment is necessary.

-12

-34

106

108

222

226

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.

NOTE

When the anti-freeze is mixed with

water, the anti-freeze mixing ratio

must be less than 50%.

Check to see whether the battery cables are loose. Poor

contact may result in poor starting or malfunctions. Always

keep the terminals firmly tightened. Coating the terminals

with a thin film of grease will help to inhibit corrosion.

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DCA-150SSKII — PRE-SETUP

Battery Cable Installation

CAUTION

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

connected to the battery terminals as shown below. The

RED cable is connected to the positive terminal of the battery,

and the BLACK cable is connected to the negative terminal

of the battery.

Inadequate battery connections may cause

poor starting of the generator, and create

other malfunctions.

Wiring

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for

wear and tightness.Tighten all hose clamps and check hoses

for leaks.

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

immediately.

Figure 41. Battery Connections

CAUTION

If the battery cable is connected

incorrectly, electrical damage to the

generator will occur. Pay close attention

to the polarity of the battery when

connecting the battery.

When connecting battery do the following:

1. ALWAYS make sure that the Off/Manual/Auto switch is

in the "OFF" position when connecting the battery. If

the generator is equipped with an ignition switch, make

sure the ignition switch is in the "OFF" postion and the

key is removed.

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will

help prevent corrosion around the battery terminals.

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DCA-150SSKII — LOAD APPLICATION

Single Phase Load

CAUTION

Motors and motor-driven equipment draw

much greater current for starting than

during operation.

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage and

frequency requirements are satisfactorily supplied by the

generator for operating the equipment.

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.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require

130—150% more wattage than the rating on the

nameplate, as the wattage is influenced by the efficiency,

power factor and starting system of the equipment.

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.

NOTE

If wattage is not given on the

equipment's name plate, approximate

wattage may be determined by

multiplying nameplate voltage by the

nameplate amperage.

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

WATTS = VOLTAGE x AMPERAGE

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

The power factor of this generator is 0.8. See Table 15.

below when connecting loads.

CAUTION:

Table 15. Power Factor By Load

Before connecting this generator to any

building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious injury or death

may result without this transfer switch.

Type Of Load

Power Factor

Single-phase induction

motors

0.4 - 0.75

Electric heaters,

incandescent lamps

1.0

Fluorescent lamps, mecury

lamps

0.4 - 0.9

Electronic devices,

communication equipment

1.0

0.8

Common power tools

NOTE

Three Phase Load

When calculating the power requirements for 3-phase

power use the following equation:

output

(kVA)

not

given

on the equipment nameplate, approximate

output may be determined by multiplying

voltage by amperage by

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DCA-150SSKII — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:

2. Once it is determined if commercial power is required,

connect the load to the UNV terminals as shown in

Figure 43. These terminals can be found on the output

terminal panel, see page 33, Figure 14.To gain access

to the output terminals lift the UNV cover. Make sure to

tighten terminal nuts securely to prevent load wires from

slipping out.

The engine's exhaust contains

harmful emissions.ALWAYS ventilate

the exhaust when operating inside

tunnels, excavations or buildings.

Direct exhaust away from nearby

Before Starting

Engine

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

Make sure the generator is level. The oil level must be

maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase

with high grade motor oil. Use a high quality detergent

oil classified CC or higher (See Table 12 on page 43).

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

Replenish with antifreeze as necessary.Always maintain

the coolant level between the FULL and LOW markings

on the coolant container.Be sure that the radiator cap is

fastened securely.

Figure 43. UNV Terminal Lugs (Load)

4. Check the fuel level on the fuel gauge. If fuel is low, fill

the fuel tank with clean fresh unleaded automotive diesel.

If diesel spillage occurs, completely wipe up the spilled

fuel immediately.

Before Starting

3. Connect the negative battery cable (BLACK) to the

negative post on the battery (Figure 44).

Generator and Control Panel

CAUTION:

NEVER start the engine with the

main, GFCI or load circuit

breakers in the ON position.

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

main, load and G.F.C.I. circuit breakers (Figure 42) to

the “OFF” position prior to starting the engine.

TTER

Figure 44. Battery Connections

Figure 42. Main, GFCI and

Load Circuit Breakers

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DCA-150SSKII — GENERATOR START-UP PROCEDURE (MANUAL)

4. Close all engine enclosure doors (Figure 45).

7. After engine starts, verify that the "Engine Running"

status LED (Figure 49) on the Microprocessor Engine

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

Figure 45. Engine Enclosure Doors

5. When starting the generator in COLD weather conditions,

press and hold the engine preheat button (Figure 46)

until the pre-heat lamp (Figure 47) is lit (ON).

Figure 49. MPEC Engine Running Status LED

8. If the unit has an ignition switch(Figure 50), turn the

key to the right, until the engine starts. Then

release the key to 'Run'.

Figure 46. Engine Pre-Heat Button

Figure 50. Ignition Switch (Run)

9. Pull and turn the engine throttle lever (Figure 51) to

increase the engine speed to high.

Figure 47. Engine Pre-Heat Lamp

6. Place the Off/Manual/Auto switch (Figure 48) in the

MANUAL position (down).Observe that the engine begins

to crank.

Figure 51. Engine Throttle Lever (High)

10. If the generator is equipped without the engine

throttle lever, set the idle control switch to the "ON"

position. (See figure 52)

Figure 48. Off/Manual/Auto Switch (Manual)

Figure 52. Idle Control (ON)

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DCA-150SSKII — GENERATOR START-UP PROCEDURE (MANUAL)

11. The generator's frequency meter (Figure 53) displays 14. The engine oil pressure gauge (Figure 57) will indicate

the 60 cycle output frequency in HERTZ.

the oil pressure (kg/ cm²) of the engine. Under normal

operating conditions the oil pressure should be

approximately 25 psi.

Figure 53. Frequency Meter (Hz)

12. The generator's voltage meter (Figure 54) displays the

120 VAC in VOLTS. If the voltage is not within the

specified frequency tolerance, use the voltage

adjustment control knob (Figure 55) to increase or

decrease the desired voltage.

Figure 57. Oil Pressure Gauge

15. The coolant temperature gauge (Figure 58) will indicate

the coolant temperature. Under normal operating

conditions the coolant temperature should be between

105 and 215 degrees fahrenheit (Green Zone).

WATER TEMP

Figure 58. Coolant Temperature Gauge

Figure 54.Voltage Meter (Volts)

16. The tachometer (Figure 59) will indicate the speed of

the engine when the generator is operating. Under normal

operating conditions this speed should be approximately

1800 RPM’s.

Figure 55.Voltage Adjust Control Knob

13. The ammeter (Figure 56) will indicate zero amps with

no load applied. When a load is applied, this meter will

indicate the amount of current that the load is drawing

from the generator’s alternator.

Figure 59. Engine Tachometer

Figure 56. Ammeter (No Load)

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DCA-150SSKII — GENERATOR START-UP PROCEDURE (AUTO)

17. After the engine has been running for a few minutes,

CAUTION:

look at the status LED’S on the "MPEC" display (Figure

9) and check it for any abnormal conditions. If any

abnormal conditions exist, shut down the engine and

take corrective action to solve the problem.

Before connecting this generator to any

building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious injury or death

may result without this transfer switch.

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

LED display, turn the MAIN, GFCI and LOAD circuit

breakers to their ON position (Figure 60).

Starting the generator in the "AUTO" mode is similar to

starting the generator in the "MANUAL" mode, with a few

exceptions.

CAUTION:

When running the generator in the AUTO

mode, remember the generator can start

up at any time without warning. NEVER

attempt to perform any maintenance when

the generator is in the auto mode.

Figure 60. Main and GFCI Circuit Breakers

19. Look at the generator's ammeter (Figure 61) and verify

that it reads the anticipated amount of current with

respect to the load. Remember the ammeter will only

display a current reading if the load is in use.

If the generator is equipped with an MPEC, when starting

generator in Auto mode use the "Manual Start-up" procedure

except where noted (see below).

1. Perform steps 1 through 6 (page 47-48) as outlined in

the manual starting procedure.

2. Place the Off/Manual/Auto switch (Figure 62) in the

AUTO position (up). Observe that the engine begins to

crank.

Figure 61. Ammeter (Load)

20. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 62. Off/Manual/Auto Switch (Manual)

3. Continue to follow the steps outline in the manual start-

up procedure (start at step 9, page 48).

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Table of Contents

DCA-150SSKII — GENERATOR SHUT-DOWN PROCEDURE

Engine Shutdown

To shut-down the generator use the following procedure:

6. Verify that the "Engine Running" status LED (Figure

66) on the Microprocessor Engine Control Module

(MPEC) display is "OFF" (not lit).

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

to the "OFF position"

2. Turn the Engine Throttle Handle (Figure 63)to the left and

push in to set the speed to 'low'.

Figure 66. MPEC Engine Running

Status LED (OFF)

Figure 63. Engine Throttle Lever (low)

7. If the generator is equipped with an ignition switch, (Figure

67) turn the key to the left to the "OFF" positionturn off

the engine.

3. If the generator is equipped with an idle control switch, set

the switch to "OFF" positon. (Figure 64)

Figure 67. Off/Manual Auto Switch (OFF)

Figure 64. Idle Control Switch (OFF)

8. Remove the load from the UNVO terminal strip (Figure 14 -

page 33).

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

load applied.

5. Place the Off/Manual/Auto Switch (Figure 65) in the "OFF/

RESET" position.

Figure 65. Off/Manual Auto Switch (OFF)

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 51

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Table of Contents

DCA-150SSKII — MAINTENANCE

General Inspection

Cleaning the Fuel Strainer

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.

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.

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

Instruction Manual)

Check Oil Level

Check the crankcase oil level prior to each use, or when the

fuel tank is filled. Insufficient oil may cause severe damage

to the engine. Make sure the generator is level.The oil level

must be between the two notches on the dipstick as shown

in Figure 39 on page 43.

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy

duty paper element with kerosene, or foam element with

liquid detergent and hot water. Wrap foam element in a cloth

and squeeze dry. For heavy duty paper element, wipe

excess kerosene with towel.

Generator Storage

For storage of the generator for over 30 days, the following

is required:

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations). Always pour through the mesh filter.

Drain the fuel tank completely.

Run the engine until the fuel completely consumed.

Removing Water from theTank

Completely drain the oil from the crankcase and refill

with fresh oil.

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.

Stop the engine at the compression point.

Clean all external parts of the generator with a cloth.

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

Air Removal

If air enters the fuel injection system of a diesel engine,

starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system

according to the following procedure.

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

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

This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions,

a clogged air cleaner will result in high fuel consumption,

loss of power and excessive carbon buildup in the

combustion chamber.

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Table of Contents

DCA-150SSKII — MAINTENANCE

TABLE 16.

10 Hrs

DAILY

250 Hrs

500 Hrs 1000 Hrs

INSPECTION / MAINTENANCE

Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

Check for Leaks

Check for Loosening of Parts

Replace Engine Oil and Filter *¹

Clean Air Filter

ENGINE

Drain Bottom of Fuel Tank

Clean Unit, Inside and Outside

Change Fuel Filter *²

Clean Radiator and Check Coolant

Protection Level

Replace Air Filter Element

Change Corrosion Resistor

Check all Hoses and Clamps

Clean Inside of Fuel Tank

Measure Insulation Resistance Over

3M ohms

GENERATOR

*¹Replace engine oil anf filter at 100 hours, first time only.

*²Replace fuel filter at 250 Hours, first time only.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 53

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Table of Contents

DCA-150SSKII —TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper diagnosis based on the EngineTroubleshooting (Table 17).If

handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's

breakdown, use the tables shown for

business office or service plant.

TABLE 17. ENGINE TROUBLESHOOTING

SYMPTOM

POSSIBLE PROBLEM

No fuel?

SOLUTION

Replenish fuel.

Air in the fuel system?

Water in the fuel system?

Fuel pipe clogged?

Bleed system.

Remove water from fuel tank.

Clean fuel pipe.

Fuel filter clogged?

Clean or change fuel filter.

Excessively high viscosity

of fuel or engine oil at low

temperature?

Use the specified fuel or engine oil.

Fuel with low cetane

number?

Use the specified fuel.

Tighten nut.

Fuel leak due to loose

injection pipe retaining nut?

Incorrect injection timing?

Fuel cam shaft worn?

Adjust.

Engine does not start.

Replace.

Injection nozzle clogged?

Clean injection nozzle.

Injection pump

malfunctioning?

Repair or replace.

Seizure of crankshaft,

camshaft, piston, cylinder

liner or bearing?

Compression leak from

cylinder?

Replace head gasket, tighten cylinder head bolt, glow

plug and nozzle holder.

Improper valve timing?

Correct or replace timing gear.

Replace.

Piston ring and liner worn?

Excessive valve clearance? Adjust.

Starter malfunctioning?

Wiring disconnected?

Repair or replace.

Connect wiring.

Starter does not run.

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DCA-150SSKII —TROUBLESHOOTING (ENGINE)

TABLE 17. ENGINE TROUBLESHOOTING (CONTINUED)

SYMPTOM

POSSIBLE PROBLEM

Fuel filter clogged or dirty?

Air cleaner clogged?

SOLUTION

Clean or change.

Fuel leak due to loose

injection pipe retaining nut?

Tighten nut.

Injection pump

malfunctioning?

Repair or replace.

Adjust.

Engine revolution is not

smooth.

Incorrect nozzle opening

pressure?

Injection nozzle stuck or

clogged?

Repair or replace.

Fuel over flow pipe

clogged?

Clean.

Governor malfunctioning?

Excessive engine oil?

Repair.

Reduce to the specified level.

Repair or replace.

Piston ring and liner worn

or stuck?

Either white or blue exhaust

gas is observed.

Incorrect injection timing?

Deficient compression?

Overload?

Adjust.

Adjust top clearance.

Lessen the load.

Use the specified fuel.

Clean or change.

Repair or replace the nozzle.

Adjust.

Low grade fuel used?

Fuel filter clogged?

Either black or dark gray

exhaust gas is observed.

Air cleaner clogged?

Deficient nozzle injection?

Incorrect injection timing?

Engine's moving parts

seem to be seizing?

Repair or replace.

Deficient output.

Uneven fuel injection?

Repair or replace the injection pump.

Repair or replace the nozzle.

Deficient nozzle injection?

Replace head gasket, tighten cylinder head bolt, glow

plug and nozzle holder.

Compression leak?

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Table of Contents

DCA-150SSKII —TROUBLESHOOTING (GENERATOR/ENGINE)

diagnosis based on the Engine and Radiator Troubleshooting

(Table 18) and the MPEC Troubleshooting (Table 19). If the

problem cannot be remedied, consult our company's

business office or service plant.

Practically all breakdowns can be prevented by proper

handling and maintenance inspections, but in the event of a

breakdown, use the tables shown for

TABLE 18. ENGINE & GENERATOR TROUBLESHOOTING

SYMPTOM

POSSIBLE PROBLEM

SOLUTION

Dead battery?

Replace battery.

Replace switch.

Replace fuse.

Engine fails to start and

starter does not rotated.

Defective starter switch?

Fuse F5 burned out?

Broken pre-heat circuit?

No fuel?

Check pre-heat circuit.

Add fuel.

Engine fails to start and

starter rotates.

Defective wiring?

Check wiring.

Clogged fuel strainer?

Clogged air cleaner?

Disconnected wiring?

Clean or replace.

Check and repair wiring.

Engine starts and remains at

low speed.

No voltage present in AC

power source?

Replace rectifier (RE1).

Defective rotor?

Replace rotor.

Engine speed rises and no

volteage is present n AC

power source.

Defective voltmeter?

Disconnected wiring?

Replace voltmeter.

Check and repair wiring.

Layer short-circuit in armature

winding?

Replace armature.

Defective circuit breaker

(protector)?

Replace circuit breaker (protector).

Repair or replace armature.

Engine speed rises and AC

power voltage is too low or

cannot be used.

Layer short-circuit, broken

wires in armature winding?

Defective engine regulator?

Defective wiring?

Replace regulator.

Engine speed rises and

battery discharges too soon.

Repair or replace wiring.

Repair or replace alternator.

Replace alternator bearings.

Defective alternator?

Engine speed rises and

engine seems overloaded.

Damaged alternator bearing?

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Table of Contents

DCA-150SSKII —TROUBLESHOOTING (MPEC)

TABLE 19. MPEC TROUBLESHOOTING

Sympton

Possible Cause

Low oil level?

Solution

Fill oil level.

Oil pressure sending unit failure?

Time delay malfuntion in MPEC?

Wire shorted?

Replace oil pressure sending unit.

Refer to dealer.

Low oil pressure

light is on.

Inspect/repair wire.

Fill coolant level.

Low coolant level?

Low coolant level

light is on.

Sending unit failure?

Replace sending unit.

Replace/charge battery.

Tighten/replace fan belt.

Low battery voltage?

Fan belt tension incorrect?

Air flow is not circulation through

radiator?

Clean/repair radiator grill.

Doors open?

Close doors.

High coolant

temperture light is

on.

Exhaust leaking?

Replace/repair gaskets or faulty part.

Check/reduce load.

Replace thermostat.

Clear all air intakes.

Replace temperature switch.

Fill fuel level.

Generator being overloaded?

Thermostat failure?

Air intake blocked?

Temperature switch failure?

No or low Fuel?

Overcrank light is

on.

MPEC needs to be calibrated?

RPM engine speed too high?

Refer to dealer.

Adjust RPM.

Governor actuator needs to be adjusted? Adjust governor actuator.

Overspeed light is

on.

Governor controller needs to be

Adjust governor controller.

adjusted?

MPEC needs to be calibrated?

Magnetic pick up out of adjustment?

Magnetic pick up dirty?

Refer to dealer.

Adjust magnetic pick up.

Clean magnetic pick up.

Loss of MPU

light(s) or on.

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 57

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Table of Contents

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts

book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial

number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the

corresponding part is utilized only with this specific model

number or model number variant.

Items Found In the“Items Number”Column

All parts with same symbol in the number column, , #,

, belong to the same assembly or kit.

, %, or

■

NOTE

If more than one of the same reference number is

listed, the last one listed indicates newest (or latest)

part available.

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Table of Contents

DCA-150SSKII — SUGGESTED SPARE PARTS

DCA-150SSKIIW/KOMATSU S6D108E-2 ENGINE

1 to 5 Units

Qty.

P/N

Description

1 ......... 0601807346 ......... CIRCUIT BREAKER

1 ......... 0601840073 ......... RHEOSTAT (VOLTAGE REGULAR)

1 ......... 0601840121 ......... KNOB FOR RHEOSTAT

2 ......... 0601812598 ......... RECEPTACLE 530 EM

1 ......... 0601812565 ......... RECTIFIER

3 ......... 0602041147 ......... OIL FILTER CARTRIDGE

1 ......... 0810105004 ......... FUEL TANK CAP

3 ......... 0602042146 ......... FUEL FILTER CARTDIDGE

3 ......... 0602046338 ......... ELEMENT, AIR INNER

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

3 ......... 615 ...................... KEY, IGNITION

1 ......... 0602123087 ......... WATER TEMPERATURE GAUGE

1 ......... 0602122037 ......... OIL PRESSURE GAUGE

1 ......... 0602122251 ......... OIL SHUT-DOWN SENDING UNIT

1 ......... 0602123250 ......... WATER TEMPERATURE SENDING UNIT

3 ......... 0601822034 ......... RECEPTACLE, CS 6369 250V, 50 AMPS

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 59

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DCA-150SSKII— GENERATOR ASSY.

GENERATOR ASSY.

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Generator

DCA-150SSKII— GENERATOR ASSY.

GENERATOR ASSY.

NO.

PART NO.

8151000312

PART NAME

QTY.

REMARKS

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

1-1*

1-2*

1-3*

1-4*

1-5*

1-6*

1-7*

1-8*

1-9*

FIELD ASSY

FAN

8131070013

012010030

030210250

8131611004

8131015003

0012112035

0042612000

8101026013

HEX HEAD BOLT ......................... 12 ..........REPLACES 0012110030

LOCKWASHER............................ 12 ..........REPLACES 0042510000

COUPLING DISK

BALANCING PLATE

HEX HEAD BOLT

LOCKWASHER

SET PLATE RECTIFIER

1-10* 0601821349

1-11* 0601822601

1-12* 8001020004

1-13* 8001020504

1-14* 0010110020

1-15* 0040010000

1-16* 0601000209

1-17* 0071906312

RECTIFIER .................................... 2 ..........PT3610

SURGE ABSORBER...................... 1 ..........ERZ -M14JK621A

INSULATORWASHER

HEX HEAD BOLT

LOCKWASHER

BALANCING WEIGHT KIT

BEARING

STATOR ASSY

GROMMET

END BRACKET

8151340213

0845041804

8131315102

8101350013

0012110060

0042610000

031110160

0010112035

0040012000

031112230

8131310114

8131312214

8101331003

0105050616

8101333003

0010106030

0040006000

952404470

012010030

030210250

8131332003

0605000063

0030016000

0040016000

Full View

FIELD ASSY, EXCITER

HEX HEAD BOLT

LOCKWASHER

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

HEX HEAD BOLT

LOCKWASHER

PLAIN WASHER ............................. 6 ..........REPLACES 0041212000

COVER, BEARING

GASKET, BEARING

COVER, END BRACKET

HEX HEAD BOLT ......................... 10 ..........REPLACES 0017106012

COVER, END BRACKET

HEX HEAD BOLT

LOCKWASHER

PLAIN WASHER ............................. 2 ..........REPLACES 0041206000

HEX HEAD BOLT ......................... 12 ..........REPLACES 0012110030

LOCKWASHER............................ 12 ..........REPLACES 0042510000

COVER, FAN

RUBBER SUSPENSION

HEX NUT

LOCKWASHER

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 61

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DCA-150SSKII — CONTROL BOX ASSY.

CONTROL BOX ASSY.

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Control Box

Table of Contents

DCA-150SSKII — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO.

PART NO.

PART NAME

CONTROL BOX

CURRENTTRANSFORMER ........ 2 ........ CT-3.5MR300/SA

MACHINE SCREW

OVER CURRENT RELAY ............. 1 ........ TH-K20

MACHINE SCREW

CIRCUIT BREAKER ..................... 1 ........ XE400NS 400A

MACHINE SCREW

LOCKWASHER

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

AUTO.VOLTAGE REGULATOR..... 1 ........NTA-5A-2T

QTY. REMARKS

C0214001202

0601801148

0027104010

0601820851

0027104016

0601807346

0021006040

0440006000

952404470

0601820671

0017105016

6008151252

0017106016

0601823860

0027104010

0601823706

0027104010

0601823861

0027104010

6008152970

0017106016

0601824542

0227103010

0602201911

0017104016

M3923100014

8151839504

8151839714

0021304020

0021306020

011008020

HEX HEAD BOLT

EMERGENGY RELAY ................. 1 ........REPLACES 0602200446

HEX HEAD BOLT

RELAY UNIT ................................ 2 ........MSA9013

MACHINE SCREW

RELAY .......................................... 1 ........HE1A DC24V

MACHINE SCREW

STOP UNIT .................................. 1 ........MSA9014

MACHINE SCREW

GLOW RELAY .............................. 1 ........REPLACES 0602201227

HEX HEAD BOLT

RELAY .......................................... 1 ........HH62S DC24V

MACHINE SCREW

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

MACHINE SCREW

SELECTOR SWITCH ................... 1 ........VY200/S1; REPLACES 8150153114

SET PLATE, SELEC. SWITCH

BRACKET, SELECTOR SWITCH 1

Full View

MACHINE SCREW

HEX HEAD BOLT ......................... 2 ........REPLACES 0017108020

020108060

HEX NUT ...................................... 2 ........REPLACES 0207008000

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 63

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DCA-150SSKII— CONTROL BOX ASSY.

CONTROL BOX ASSY.

PAGE 64 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Control Box

Table of Contents

DCA-150SSKII— CONTROL BOX ASSY.

CONTROL BOX ASSY. (CONT.)

NO.

PART NO.

PART NAME

CONTROL PANEL

QTY.

REMARKS

C0224001403

0605011211

0601800487

0601808901

0601801040

0601800298

0601801041

0601810072

0601810261

0601840073

0601840121

0601810161

0601810214

0030004000

0601830710

C9221100004

0040008000

031108160

0080100007

3871824004

952404470

505015300

C0214500104

011008020

8361827504

011008020

FREQUENCY METER ...............................1............TRC- 65CF 220V 45 ~65HZ

AC AMMETER ...........................................1............TRS- 65C0 ~300A0 ~600A

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

AC VOLTMETER ........................................1............TRR - 65C0 ~600V

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

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

BULB ..........................................................1............CT - 13W

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

KNOB

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

BULB

HEX NUT ....................................................2............REPLACES 0207004000

SWITCH, PANEL LIGHT

HEX HEAD BOLT

LOCKWASHER

PLAIN WASHER .........................................2............REPLACES 0041208000

SNAP RING

STOPPER, CONTROL PANEL

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

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

COVER, CONTROL BOX

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

PANEL, CONTROL BOX

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

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

Full View

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 65

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Table of Contents

DCA-150SSKII— ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

PAGE 66 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Table of Contents

Engine and Radiator

DCA-150SSKII— ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO.

PART NO.

PART NAME

QTY. REMARKS

C0924200084

ENGINE.......................................... 1 ...... KOMATSU S6D 108E - 2

INCLUDE ITEMS W/*

1-1*

1-2*

1-3*

1-4*

6001816740

6136515121

6003118293

6004111191

ELEMENT, AIR CLEANER ............. 1 ....... REPLACES 0602046338

CARTRIDGE, OIL FILTER ............. 1 ....... REPLACES 0602041147

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

CARTRIDGE., CORROSION

RESISTOR ..................................... 1 ....... REPLACES 0602045141

DUST SENSOR.............................. 1 ....... REX01 - 8126

RADIATOR ...................................... 1 ....... REPLACES 0602011866

RUBBER SHEET............................ 2 ....... REPLACES 0605000073

1-5*

0602040678

6151619350

6151619340

00100120605

0030012000

031112230

HEX HEAD BOLT

HEX NUT

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

C0311100004

0017110025

6221619320

6221619330

0726020971

0728100909

0728100809

0728101029

0728100197

0605000060

0030012000

0040012000

C9101000104

0802024004

0805008004

0802025104

C0321200004

C0321300004

011208025

BRACKET, RADIATOR

HEX HEAD BOLT

RADIATOR HOSE........................... 1 ....... REPLACES 0602014543

RADIATOR HOSE........................... 1 ....... REPLACES 0602014425

RADIATOR HOSE........................... 1 ....... REPLACES 0602014544

HOSE BAND .................................. 1 ....... REPLACES 0602014056

HOSE BAND .................................. 2 ....... REPLACES 0602014067

HOSE BAND .................................. 1 ....... REPLACES 0602014350

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

RUBBER SUSPENSION

HEX NUT

LOCKWASHER

DRAIN JOINT

PACKING, OIL PAN SIDE

PACKING

JOINT BOLT

DRAIN JOINT

DRAIN PLUG

Full View

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

ELBOW JOINT, 3/4

LONG NIPPLE

VALVE ............................................1 ........ BBS22020

HOSE JOINT

0130008000

0134308100

0603325017

0602022294

0265800850

DRAIN HOSE

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 67

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DCA-150SSKII— ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

PAGE 68 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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DCA-150SSKII— ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY. (CONT)

NO.

PART NO.

PART NAME

HOSE BAND

QTY. REMARKS

0605515074

08020810030

0802010900

8302082103

0021108020

020108060

0199601200

0193601200

0605515013

0193600450

0193600800

0268200900

0605515132

8302256104

8152256104

012210020

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

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

BRACKET, RESERVE TANK

MACHINE SCREW

HEX NUT ....................................... 2 ........ REPLACES 0207008000

HOSE

HOSE BAND

HOSE

HOSE BAND

CLAMPER ROD

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

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 69

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DCA-150SSKII — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

PAGE 70 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Engine Operating Panel

Table of Contents

DCA-150SSKII — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO.

PART NO.

PART NAME

QTY. REMARKS

C0352100803

0017106016

0207006000

0602120558

0602120701

0602129032

0602120069

0602122037

0602123087

0602121060

0602115031

0602129031

0021806020

0021806050

0602120129

0602122251

0602123250

8132142004

0601840190

0036003000

7452140504

0030008000

0605010503

6008155390

OPERATING PANEL

HEX HEAD BOLT

HEX NUT

METER PANEL ASS’Y................... 1 ...... 1573708760;INCLUDE ITEMW/*

WIRING HARNESS

METER PANEL .............................. 1 ...... 0577764130

TACHOMETER ............................... 1 ...... 1005694600

OIL PRESSURE GAUGE ............... 1 ...... 1005760430

WATER TEMP. GAUGE .................. 1 ...... 1005752740

CHARGING AMMETER ................. 1 ...... 1005730330

INDICATOR ASS’Y ......................... 1 ...... 0559004040

MACHINE SCREW

4-1*

4-2*

4-3*

4-4*

4-5*

4-6*

4-7*

CABLE, TACHOMETER ................. 1 ...... 0578909990

UNIT, OIL PRESSURE ................... 1 ...... 0716000760

UNIT, WATER TEMPERATURE ...... 1 ...... 0715000331

Full View

SLIDE LEVER

KNOB ............................................. 1 ...... REPLACES 0805012904

HEX NUT

BRACKET

HEX NUT

SNAP PIN

STARTER SWITCH ........................ 1 ......REPLACES 0602100049

INCLUDE ITEM W/#

16-1# 0000000615

KEY, STARTER SWITCH

6008152371

C0355300114

0602180106

0030004000

0207006000

952404470

C0355200204

0017112025

C0484000303

0017110025

0207010000

PREHEATLAMP ............................. 1 ...... REPLACES 0602102047

GOVERNOR ROD

BALL JOINT

HEX NUT

PLAIN WASHER ............................. 2 ...... REPLACES 0041206000

ROD GUIDE

HEX HEAD BOLT

SUPPORT LEG

HEX HEAD BOLT

HEX NUT

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 71

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DCA-150SSKII — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

PAGE 72 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Engine Operating Panel

Table of Contents

DCA-150SSKII — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.(CONT)

NO.

PART NO.

PART NAME

QTY. REMARKS

8131860303

0801830304

0801830804

0039316000

0040016000

0041416000

011208035

8131865704

0605010051

0027103010

0027103016

0207003000

0017106016

0845032104

0845032004

011008020

0601812597

0601811034

0021304015

0030004000

031104080

06018053136

0601805840

8131817103

0223300200

011206020

8131865303

012212045

031112230

0805009804

0030012000

SET BOARD, OUTPUT TERM.

OUTPUTTERMINAL

HEX HEAD BOLT

HEX NUT

LOCKWASHER

PLAIN WASHER

HEX HEAD BOLT ............................ 5 .............REPLACES 0017108035

COVER OUTPUT TERMINAL

HINGE

MACHINE SCREW

HEX NUT

HEX HEAD BOLT

RUBBER COVER

SET FRAME RUBBER COVER

Full View

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

RECEPTACLE ................................. 2 .............530EM; REPLACES 0601812598

RECEPTACLE ................................. 3 .............CS6369; REPLACES 0601812565

MACHINE SCREW........................ 10 .............REPLACES 0027104015

HEX NUT

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

CIRCUIT BREAKER ........................ 2 .............KM-51265V20A

CIRCUIT BREAKER ........................ 3 .............KM-52265V50A

BRACKET CIRCUIT BREAKER

RUBBER CUSHION

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

COVER

HEX HEAD BOLT ............................ 2 .............REPLACES 0010012045

PLAIN WASHER .............................. 2 .............REPLACES 0041212000

47-1

RUBBERWASHER

HEX NUT

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 73

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DCA-150SSKII — BATTERY ASSY.

BATTERY ASSY.

PAGE 74 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Battery

DCA-150SSKII — BATTERY ASSY.

BATTERY ASSY.

NO.

PART NO.

PART NAME

BATTERY ....................................... 2 ...... 115F51

BATTERY SHEET

BATTERY BAND

BATTERY BOLT

WING NUT

QTY. REMARKS

0168511551

0805000804

0805000904

0805002904

0037808000

0040008000

0041208000

0602220203

C0347500004

8302265304

8302265504

C0347200104

012010030

020310080

012212025

0040012000

031112230

0040512000

0845040414

0845041304

LOCKWASHER

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

BATTERY SENSOR

BATTERY CABLE

EARTH CABLE

HEX HEAD BOLT ........................... 4 ...... REPLACES 0010010030

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

HEX HEAD BOLT ........................... 1 ...... REPLACES 0010012025

Full View

LOCKWASHER

PLAIN WASHER ............................. 1 ...... REPLACES 0041212000

TOOTHEDWASHER

TERMINAL CAP +

TERMINAL CAP -

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 75

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DCA-150SSKII — MUFFLER ASSY.

MUFFLER ASSY.

PAGE 76 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Muffler

DCA-150SSKII — MUFFLER ASSY.

MUFFLER ASSY.

NO.

PART NO.

PART NAME

MUFFLER

HEX HEAD BOLT

EXHAUST PIPE

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

HEX HEAD BOLT

HEX NUT

QTY. REMARKS

C0331100302

0017110025

C0334000003

6150115751

0012112045

0030012000

031112230

Full View

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

0010112050

0030012000

031112230

HEX HEAD BOLT

HEX NUT

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

8252354004

C0334200104

011008020

COVER

SHEET

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

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 77

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DCA-150SSKII — FUELTANK ASSY.

FUEL TANK ASSY.

PAGE 78 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Fuel Tank

DCA-150SSKII — FUELTANK ASSY.

FUEL TANK ASSY.

NO.

1-1*

PART NO.

C0364001003

0605505030

PART NAME

QTY. REMARKS

FUEL TANK .................................... 1 ...... INCLUDE ITEMS W/*

CAP FUEL TANK ............................ 1 ...... REPLACES 0605505005

KEY, CAP FUEL TANK

FUEL FILTER

HOSE, FUEL GAUGE

TANK BAND

PAD ,TANK BAND

HEX, HEAD BOLT .......................... 2 ......REPLACES 0017108020

1-2*

1-3*

0810105400

0257700385

8135523304

0805003414

011008020

020108060

0222100320

0845047504

0802011104

0150000018

0191301100

0191301200

0191001750

0605515014

0605515013

0605503009

0802120604

0845039604

HEX, NUT....................................... 2 ...... REPLACES 0037908000

TANK SHEET

DRAIN JOINT

PLUG

Full View

O RING

SUCTION HOSE

RETURN HOSE

HOSE BAND

FUEL SENSOR

PACKING

RUBBER SEAL

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 79

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DCA-150SSKII — ENCLOSURE ASSY.

ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

5 -BLACK

6 -CATERPILLARYELLOW

7 -CATO GOLD

8 -RED

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 80 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Enclosure

DCA-150SSKII — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

PART NAME

BASE

FLOOR PANEL

QTY. REMARKS

C0414001602

C0414100004

011008020

HEX, HEAD BOLT ......................... 10 ..... REPLACES 0017108020

C0424001502

C0494101203

0017110025

0845039703

011008020

8305125004

8305924104

0017108020

C0424200003

011008020

C0434000702

0010114050

020114110

030214350

031114260

FRONT FRAME

LINING

HEX, HEAD BOLT

FILLER BRACKET

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

COVER, FRONT FRAME

LINING

HEX, HEAD BOLT

COVER, FRONT FRAME

HEX, HEAD BOLT ......................... 12 ..... REPLACES 0011708020

CENTER FRAME

HEX, HEAD BOLT

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

LOCKWASHER............................... 4 ..... REPLACES 0040014000

PLAIN WASHER .............................. 4 ..... REPLACES 0041214000

0010120045

0030020000

0040020000

0041220000

C0444000802

8305940104

0017110025

8155155403

8155944104

011008020

8155156004

8155946104

011008020

8155118504

011008020

8155143703

C0444200413

B9114000102

0021806016

0030006016

8255146104

8255146204

0845050704

0207006000

8165157004

HEX, HEAD BOLT

HEX, NUT

LOCKWASHER

PLAIN WASHER

REAR FRAME

LINING

HEX, HEAD BOLT

COVER, REAR FRAME

LINING

Full View

HEX, HEAD BOLT ......................... 14 ..... REPLACES 0017108020

PANEL

LINING

HEX, HEAD BOLT ........................... 9 ..... REPLACES 0017108020

DUCT

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

DOOR, REAR FRAME

DOOR HANDLE

MACHINE SCREW

HEX, NUT

DOOR ROD

STAY

HEX, NUT

WINDOW PLATE

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 81

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DCA-150SSKII — ENCLOSURE ASSY.

ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

5 -BLACK

6 -CATERPILLARYELLOW

7 -CATO GOLD

8 -RED

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 82 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Table of Contents

Enclosure

DCA-150SSKII — ENCLOSURE ASSY.

ENCLOSURE ASSY. (CONT)

NO.

PART NO.

PART NAME

HEX. NUT

DOOR POCKET

QTY.

REMARKS

00377906000

B9114500104

0207006000

M9110100204

0845045004

M9110100304

0845045004

011008020

C0464100603

C0494500404

0845052203

C0464200203

C0494501804

011008020

C0454202102

0017108055

C0454002203

C0494403204

C0454002303

C0494403304

C0454002403

C0494403404

C0454002503

C0494403504

8135176104

8135976104

8135176004

8135976304

020108060

HEX. NUT

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

WASHER

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

WASHER

HEX. HEAD BOLT .........................6........ REPLACES 0017108020

ROOF PANEL

LINING

FILLER COVER

ROOF PANEL

LINING

HEX. HEAD BOLT .......................36 ........ REPLACES 0017108020

SPLASHER PANEL

HEX. HEAD BOLT

SIDE DOOR

LINING

SIDE DOOR

LINING

SIDE DOOR

LINING

SIDE DOOR

LINING

Full View

DUCT

LINING

DUCT

LINING

HEX. NUT ....................................21 ........ REPLACES 0207008000

B9114000002

0825007362

0021806016

020106050

DOOR HANDLE

MACHINE SCREW

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

0845046904

0845045004

0845047004

0845045004

011008020

0601850057

0021008025

0845031504

B9511200003

0021106016

HINGE

WASHER

HINGE

WASHER

HEX. HEAD BOLT .......................16 ........ REPLACES 0017108020

RUBBER CUSHION

MACHINE SCREW

CAP

EMBLEM

MACHINE SCREW

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 83

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DCA-150SSKII — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

PAGE 84 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Rubber Seals

DCA-150SSKII — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO.

PART NO.

PART NAME

QTY. REMARKS

0228901080

0228900840

0228900730

0228901080

0229201200

0228800650

0228801045

0229201190

0228100320

0228100540

RUBBER SEAL

Full View

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 85

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DCA-150SSKII — NAME PLATE AND DECALS

NAME PLATE AND DECALS

PAGE 86 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Decals

DCA-150SSKII — NAME PLATE AND DECALS

NAME PLATE ASSY.

NO.

PART NO.

PART NAME

QTY.

REMARKS

1-1

0840624904

DECAL; OPERATING PROCEDURE.................. 1 ............S-3035

CONTROL BOX GROUP

2-1

2-2

2-3

2-4

2-5

2-6

2-7

0800520100

0800520904

0800520814

0840624414

0840624504

0840624604

0840624704

0840624804

B9521100504

B9531100604

C0561103503

C251000004

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

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

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

DECAL; SELECTOR SWITCH............................ 1 ............S-3030A

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

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

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

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

DECAL;CAUTION .............................................. 1 ............B92110050

DECAL;WARNING ............................................. 1 ............B93110060

DECAL;WHISPERWATT 150 ............................. 1 ............C06110350

DECAL; SAFETY INSTRUCTIONS .................... 1 ............C2510 0000

2-8

2-9

2-10

2-11

2-12

ENGINE RADIATOR GROUP

3-1

3-2

3-3

3-4

6360610304

6360620204

B9504000404

B9504100104

DECAL;WATER .................................................. 1 ............S-1880

DECAL; OIL DRAIN PLUG ................................. 1 ............S-1885

DECAL;WARNING ............................................. 2 ............B90400040

DECAL;WARNING ............................................. 1 ............B90410010

Full View

ENGINE OPERATING PANEL GROUP

4-1

4-2

4-3

4-4

0840625004

0840625104

0840625204

0840625404

DECAL; PREHEAT LAMP .................................. 1 ............S-3036

DECAL; STARTER SWITCH .............................. 1 ............S-3037

DECAL; SPEED CONTROL HANDLE ................ 1 ............S-3038

DECAL; HANDLE POSITION ............................. 1 ............S-3040

OUTPUTTERMINAL GROUP

5-1

5-2

5-3

5-4

5-5

5-6

5-7

5-8

5-9

5-10

0840614104

0840619904

8110670323

0840627103

B1551001604

B9511100304

B9511100404

B9531100504

B9531100604

C0551001004

DECAL; GROUND .............................................. 1 ............S-2635

DECAL;DANGER ............................................... 1 ............S-2731

DECAL; RECEPTACLE & CIRCUIT BRKER. ..... 1 ............S-3046B

DECAL; CABLE JOINING .................................. 1 ............S 3245

DECAL;NOTE .................................................... 1 ............B15100160

DECAL;WARNING .............................................. 1 ............B91110030

DECAL;WARNING .............................................. 1 ............B91110040

DECAL;WARNING ............................................. 1 ............B93110050

DECAL;WARNING ............................................. 1 ............B93110060

DECAL;NOTE .................................................... 1 ............C05100100

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 87

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DCA-150SSKII — NAME PLATE AND DECALS

NAME PLATE AND DECALS

PAGE 88 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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Decals

DCA-150SSKII — NAME PLATE AND DECALS

NAME PLATE ASSY.

NO.

PART NO.

PART NAME

QTY.

REMARKS

BATTERY GROUP

6-1

6-2

0800689404

0800689504

DECAL; + ........................................................... 1 ............S-2090

DECAL; - ............................................................ 1 ............S-2091

MUFFLER GROUP

7-1

B9504200004

DECAL;WARNING ............................................. 1 ............B 90420000

FUEL TANK GROUP

8-1

8-2

8-3

1320620904

6360620004

B9504500004

DECAL; DIESEL FUEL....................................... 1 ............S-1756

DECAL; FUEL DRAIN PLUG .............................. 1 ............S-1883

DECAL;WARNING ............................................. 1 ............B 90450000

Full View

ENCLOSURE GROUP

9-1

9-2

9-3

9-4

9-5

9-6

9-7

9-8

9-9

9-10

9-11

1320610603

1320621504

0840625902

B9504000304

C0561100402

C0561101203

C0561100204

C0561100603

C0561102604

C0561101003

C0561100103

DECAL;WATER- OIL .......................................... 1 ............S-1760

DECAL; SUPPORT HOOK ................................. 2 ............S-2257

DECAL; MQ ........................................................ 1 ............S-3057

DECAL;CAUTION .............................................. 1 ............B90400030

STRIPE

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 89

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TERMS AND CONDITIONS OF SALE — PARTS

4. Freight is at the sender’s expense. All PRICINGANDREBATES

Effective: July 1, 2000

PAYMENT TERMS

partsmustbereturnedfreightprepaidto

Multiquip’sdesignatedreceivingpoint.

Terms of payment for parts are net 10 days.

Prices are subject to change without prior

notice.Pricechangesareeffectiveonaspecific

5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate

condition,intheoriginalMultiquippackage willbebilledattherevisedprice.Rebatesfor

(ifany),andwithMuiltiquippartnumbers price declines and added charges for price

FREIGHTPOLICY

All parts orders will be shipped collect or

prepaidwiththechargesaddedtotheinvoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a

signedmanifesthasbeenobtainedfromthe

carrier,andanyclaimforshortageordamage

mustbesettledbetweentheconsigneeandthe

carrier.

clearly marked.

increaseswillnotbemadeforstockonhand

atthetimeofanypricechange.

6. Thefollowingitemsarenotreturnable:

Multiquipreservestherighttoquoteandsell

directtoGovernmentagencies,andtoOriginal

EquipmentManufactureraccountswhouse

our products as integral parts of their own

products.

a. Obsolete parts. (If an item is listed

in the parts price book as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

andotherrubberparts)thatwere

purchasedmorethansixmonths

priortothereturndate.

MINIMUMORDER

SPECIALEXPEDITINGSERVICE

TheminimumchargeforordersfromMultiquip

is $15.00 net. Customers will be asked for

instructionsregardinghandlingofordersnot

meetingthisrequirement.

A$20.00to$50.00surchargewillbeaddedto

theinvoiceforspecialhandlingincludingbus

c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases

netpriceoflessthan$5.00.

where Multiquip must personally deliver the

partstothecarrier.

d. Special order items.

RETURNEDGOODSPOLICY

e. Electricalcomponents.

LIMITATIONSOFSELLER’SLIABILITY

Returnshipmentswillbeacceptedandcredit

will be allowed, subject to the following

provisions:

Paint,chemicals,andlubricants.

Multiquip shall not be liable here under for

damagesinexcessofthepurchasepriceofthe

item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental

damages.

g. Decalsandpaperproducts.

h. Items purchasedinkits.

1. AReturnedMaterialAuthorizationmust

beapprovedbyMultiquippriortoshipment.

7. Thesenderwillbenotifiedofanymaterial

receivedthatisnotacceptable.

2. ToobtainaReturnMaterialAuthorization,

alistmustbeprovidedtoMultiquipParts

Sales that defines item numbers,

quantities,anddescriptionsoftheitems

tobereturned.

8. Such material will be held for 5 working

days from notification, pending

instructions. If a reply is not received

within5days,thematerialwillbereturned

tothesenderathisexpense.

LIMITATIONOFWARRANTIES

a. Thepartsnumbersanddescriptions

mustmatchthecurrentpartsprice

list.

Nowarranties,expressorimplied,aremade

in connection with the sale of parts or trade

accessories nor as to any engine not

manufacturedbyMultiquip.Suchwarranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes not

authorizes any person to assume for it any

other obligation or liability whatever in

connectionwiththesaleofitsproducts.Apart

fromsuchwrittenstatementofwarranty,there

arenowarranties,express,impliedorstatutory,

which extend beyond the description of the

productsonthefacehereof.

9. Creditonreturnedpartswillbeissuedat

dealer net price at time of the original

purchase,lessa15%restockingcharge.

b. Thelistmustbetypedorcomputer

generated.

10. In cases where an item is accepted for

which the original purchase document

can not be determined, the price will be

basedonthelistpricethatwaseffective

twelvemonthspriortotheRMAdate.

c. Thelistmuststatethereason(s)for

thereturn.

d. The list must reference the sales

order(s)orinvoice(s)underwhich

theitemswereoriginallypurchased.

11. Credit issued will be applied to future

purchasesonly.

e. Thelistmustincludethenameand

phonenumberoftheperson

requestingtheRMA.

3. A copy of the Return Material

Authorizationmustaccompanythereturn

shipment.

PAGE 90 —DCA-150SSKII— PARTS AND OPERATION MANUAL — REV. #2 (05/08/01)

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NOTE PAGE

DCA-150SSKII — PARTS AND OPERATION MANUAL— REV. #1 (05/08/01) — PAGE 91

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PARTS AND OPERATION MANUAL

Table of Contents

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HANDWHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700

FAX: 310 - 537-3927

Manufactured for Multiquip Inc.

DENYO, MANUFACTURING, CO., USA

MULTIQUIP INC.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX:310-537-3927

E-MAIL:mq@multiquip.com

WWW:multiquip.com

Atlanta • Boise • Dallas • Houston • Newark

Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX

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